Apparatus for manufacturing parts, and related methods

ABSTRACT

Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.

RELATED APPLICATION

This application claims priority to and is a divisional application ofU.S. patent application Ser. No. 15/996,343, filed on Jun. 1, 2018 andentitled APPARATUS FOR MANUFACTURING PARTS, AND RELATED METHODS, whichissued as U.S. Pat. No. 10,940,523 on Mar. 9, 2021, the entiredisclosure of which is incorporated herein by reference.

FIELD

The present disclosure relates to apparatus for manufacturing parts andrelated methods, namely, forging dies for forging parts, methods ofmaking said forging dies, and methods of making a part using saidforging dies.

BACKGROUND

Parts may be manufactured by a forging process, wherein metal is shapedin a forging die using localized compressive forces and/or heating ofthe die and/or metal. Forging dies are typically made by removingmaterial from a solid block of an expensive grade of steel (oftenreferred to as tool steel) to form a cavity therein. The process ofmaking forging dies is often slow and time consuming, as the tool steelis difficult to cut and remove to form the cavity. The tools used to cutcavities in forging dies may suffer from low cutting tool life, due tothe properties of the tool steel being cut. In addition, the materialsfor making forging dies generally are expensive and difficult to source.Furthermore, storage and maintenance costs for forging dies are oftenhigh, as forging dies may require storage and/or refurbishment betweenuses, such as re-cutting, dressing, and/or after-forging operations.Some parts may require multiple different forging dies to arrive at thefinished part, even further increasing costs. Thus, while forged partsoften have desirable mechanical properties, the process of obtainingsuch parts may be costly, time-consuming, and undesirable.

SUMMARY

Presently disclosed forging dies may reduce the time and/or costsassociated with manufacturing a forging die. Presently disclosed forgingdies advantageously may avoid storage costs, as they may be configuredto be essentially disposable, due to their speed and cost-efficiency.Such forging dies may additionally avoid refurbishment needs, in someexamples. Presently disclosed forging dies may additionally easemaintenance costs and difficulty associated with repairing worn ordamaged forging dies, and/or may reduce machining time and costsassociated with making forging dies. Generally, presently disclosedforging dies are made by cutting individual layers of material to formsections of the die cavity and then stacking the cut layers together toform the die cavities, as opposed to cutting the die cavities into asolid block of material.

Such presently disclosed forging dies generally include a first die halfand a second die half, with the second die half and the first die halfbeing configured to cooperate with one another such that a first diecavity formed in the first die half faces the second die half. The firstdie cavity is configured to receive at least a portion of a preform(e.g., a billet, a bar, a blank, or any other preform), and the forgingdie is configured to forge the part from the preform when the first diehalf and the second die half are pressed together. The first die halfincludes at least a first layer cut to form a first portion of a firstdie cavity and a second layer cut to form a second portion of the firstdie cavity, and may include additional layers cut to form additionallayers of the first die cavity, stacked between the first and secondlayers. The first layer and the second layer (and any additional layersof the first die half) are configured to be stacked together such thatthe first portion of the first die cavity and the second portion of thefirst die cavity are aligned with respect to one another to form thefirst die cavity. A first plurality of fasteners are positioned tofasten the first layer and the second layer (and any additional layersof the first die half) together to form the first die half. In someexamples, the second die half is a solid die half having a flat surfacethat engages the first die half. In other examples, the second die halfalso is formed of a plurality of layers, where each layer is cut to forma section, or portion, of a second die cavity in the second die half. Insuch cases, a second plurality of fasteners is positioned to fasten thelayers of the second die half together. The first die half and thesecond die half may be pressed together (such as in a forging press) toshape a billet, blank, bar, or other preform, into a forged part.

Methods of making a forging die for forging a part from a preformgenerally include forming a first die half and engaging the first diehalf with a second die half such that the first die cavity faces thesecond die half. The first die cavity is configured to receive at leasta portion of the preform, and the forging die is configured to forge thepart from the preform when the first die half and the second die halfare pressed together. Forming the first die half generally includescutting a first layer to form a first portion of a first die cavity,cutting a second layer to form a second portion of the first die cavity,stacking the first layer and the second layer together such that thefirst portion of the first die cavity and the second portion of thefirst die cavity are positioned with respect to one another to form thefirst die cavity, and fastening the first layer and the second layertogether to form the first die half. Methods also may include similarlyforming a second die cavity in the second die half, though in someexamples, the second die half may be a flat surface or solid block ofmaterial. Methods of making parts using such disclosed forging dies alsoare disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic black-box representation of examples of systemsincluding forging dies according to the present disclosure.

FIG. 2 is a perspective view of an example of a forging die according tothe present disclosure.

FIG. 3 is a perspective view of an example of a preform that may beshaped in forging dies according to the present disclosure.

FIG. 4 is a perspective view of another example of a preform that may beshaped in forging dies according to the present disclosure.

FIG. 5 is a perspective view of another example of a preform that may beshaped in forging dies according to the present disclosure.

FIG. 6 is a perspective view of an example of a part that may be forgedfrom a preform, in presently disclosed forging dies.

FIG. 7 is a partial cut-away view of an example of a first die half of aforging die according to the present disclosure.

FIG. 8 is a partial cut-away, exploded view of an example of a forgingdie according to the present disclosure, showing a preform that may beshaped in the forging die.

FIG. 9 is an exploded, cut-away view of a portion of a first die half ofa forging die according to the present disclosure.

FIG. 10 is a partial cutaway view of the first layer of the first diehalf of FIG. 9.

FIG. 11 is a partial cutaway view of another layer of the first die halfof FIG. 9.

FIG. 12 is a partial cutaway view of yet another layer of the first diehalf of FIG. 9.

FIG. 13 is a flowchart schematically representing methods of makingforging dies, according to the present disclosure.

FIG. 14 is a flowchart schematically representing methods of making apart using forging dies, according to the present disclosure.

DESCRIPTION

Contrary to conventional forging dies, which are milled from solidblocks of material, presently disclosed forging dies may be assembledfrom individual layers of material, which may save on time and costs ascompared to conventional forging dies, as will be detailed below. FIG. 1schematically illustrates examples of system 10, which generallyincludes a forging die 12 formed of a first die half 14 and a second diehalf 16. First die half 14 and/or second die half 16 may include a diecavity (e.g., a first die cavity 18 formed in first die half 14 and/or asecond die cavity 20 formed in second die half 16) configured to receiveat least a portion of a preform 22. When so configured, first die half14 and second die half 16 may be pressed together, thereby forcingpreform 22 to be shaped into the desired part in the forging process.Generally, in the figures, elements that are likely to be included in agiven example are illustrated in solid lines, while elements that areoptional to a given example are illustrated in broken lines. However,elements that are illustrated in solid lines are not essential to allexamples of the present disclosure, and an element shown in solid linesmay be omitted from a particular example without departing from thescope of the present disclosure.

First die half 14 is formed from a plurality of individual layers 15assembled together to form first die half 14. For example, first diehalf 14 includes at least a first layer 24 cut to form a first portion26 of first die cavity 18, and a second layer 28 cut to form a secondportion 30 of first die cavity 18. Respective layers 15 may each be cutdifferently, such that when the layers are stacked together, the cutportions (e.g., first portion 26 and second portion 30 of first diecavity 18) together form first die cavity 18. In other words, firstlayer 24 and second layer 28 are configured to be stacked together suchthat first portion 26 of first die cavity 18 and second portion 30 offirst die cavity 18 are aligned and positioned with respect to oneanother to form first die cavity 18. A first plurality of fasteners 32may be configured to fasten the respective layers 15 of first die half14 together. For example, first plurality of fasteners 32 secure firstlayer 24, second layer 28, and any intervening layers 36 (e.g., layers36 a, 36 b, and 36 c, each of which are examples of layers 15) togetherto form first die half 14. Each respective fastener of first pluralityof fasteners 32 may extend through some or all of one or more layers 15of first die half 14, but together function to assemble layers 15 withrespect to one another and to resist or prevent movement of respectivelayers 15 with respect to one another, such that the respective layers15 are positioned with respect to one another to maintain the desiredalignment of cut portions, thereby forming first die cavity 18.Additionally or alternatively, respective layers of first die half 14may be secured together by other suitable means, such as by usingadhesives. In some examples, a filler material may be included betweenlayers, such as in cases where the surfaces of the layers are not flator smooth. The layers of first die half 14 and second die half 16generally are not welded or brazed together, but welding (e.g., edge orplug welding) or brazing may be used in some examples. For example, oneor more layers 15 or portions of layers may be welded together to reducestress in a given layer 15, and/or to prevent local separation ofadjacent respective layers 15 due to localized prying forces. First diecavity 18 is generally shaped in accordance with the desired size,shape, and contours of the desired finished part to be forged in forgingdie 12, and is configured to receive at least a portion of preform 22.

First die half 14 and second die half 16 are configured to engage and/orcooperate with one another such that first die cavity 18 faces seconddie half 16 when first die half 14 and second die half 16 are pressedtogether to forge the part. Some examples of forging die 12 may includeone or more alignment pins or other alignment structures configured toensure proper alignment of first die half 14 with second die half 16. Insome examples, first die half 14 is configured to receive substantiallythe entire preform 22 within first die cavity 18, such that duringforging, second die half 16 presses preform 22 into first die cavity 18,thereby shaping preform 22. In these cases, second die half 16 may besubstantially solid, and/or may have a second engagement surface 34,which may be substantially flat or raised, for engaging first die half14 when the two die halves 14, 16 are pressed together to forge thepart. In other examples, second die half 16 includes second die cavity20, which may be configured to receive a portion of preform 22, with thedie halves 14, 16 being arranged with respect to one another such thatfirst die cavity 18 faces and is aligned with second die cavity 20, withrespective portions of preform 22 being positioned within first diecavity 18 and second die cavity 20 during forging. In such anarrangement, second engagement surface 34 of second die half 16 may facea first engagement surface 35 of first die half 14, may be positionedadjacent first engagement surface 35, and/or may be brought into contactwith first engagement surface 35. In some examples, first engagementsurface 35 is an upper surface of first layer 24 of first die half 14,and second engagement surface 34 is a lower surface of third layer 44 ofsecond die half 16. In some examples, a portion of first engagementsurface 35 may be raised with respect to other areas of first engagementsurface 35, such as in an area surrounding first die cavity 18.Additionally or alternatively, a portion of second engagement surface 34may be raised with respect to other areas of second engagement surface34, such as in an area surrounding second die cavity 20.

First die half 14 may include any suitable number of layers 15. Forclarity of description herein, first layer 24 is identified as therespective layer 15 forming the “upper” (as illustrated, but notlimiting in terms of orientation of the die half) layer of first diehalf 14, and second layer 28 is identified as the respective layer 15forming the “lower” (as illustrated) layer of first die half 14. Suchconventions will be consistent throughout the present disclosure, andgenerally refer to the orientations of the respective die halves whenthey are arranged for engagement with one another.

First layer 24 is opposite second layer 28, and first die half 14 mayoptionally include one or more additional, or intervening, layers 36(which are examples of layers 15) positioned between first layer 24 andsecond layer 28. For example, FIG. 1 illustrates three such interveninglayers 36 in broken lines: layer 36 a, layer 36 b, and layer 36 c. Otherexamples of first die half 14 may include more or fewer interveninglayers 36 positioned between first layer 24 and second layer 28. In someexamples, first die half 14 includes just first layer 24 and secondlayer 28 without any intervening layers 36 positioned therebetween. Insome examples, first die half 14 includes a single intervening layer 36(e.g., layer 36 a) positioned between first layer 24 and second layer28. In other examples, first die half 14 includes at least twointervening layers 36, at least three intervening layers 36, at leastfour intervening layers 36, at least five intervening layers 36, atleast six intervening layers 36, at least seven intervening layers 36,at least eight intervening layers 36, at least nine intervening layers36, at least ten intervening layers 36, at least 12 intervening layers36, at least 15 intervening layers 36, at least 20 intervening layers36, and/or at least 25 intervening layers 36. In yet other examples,more intervening layers 36 may be included. First die half 14 of forgingdie 12 may be selectively customizable, such that the number of layers15, the thickness of different respective layers 15, and/or thematerials used to form different respective layers 15 (or differentfirst die halves 14) may be variable depending on, for example, thegeometry, contours, or other properties of the part to be forged. Insome examples, the number and thickness of respective layers of firstdie half 14 may be varied according to the part geometry to minimize thepresence of thin plate sections and/or small radii in the respective cutportions of the respective layers.

Each intervening layer 36 may be cut to form an additional respectiveportion of first die cavity 18 and may be configured to be stackedbetween first layer 24 and second layer 28 such that the additionalrespective portions of first die cavity 18 are positioned with respectto first portion 26 and second portion 30 to form first die cavity 18.For example, intervening layer 36 a may be cut to form a third portion38 of first die cavity 18, intervening layer 36 b may be cut to form afourth portion 40 of first die cavity 18, and intervening layer 36 c maybe cut to form a fifth portion 42 of first die cavity 18, and so on.

In some examples, both first die half 14 and second die half 16 areassembled from a plurality of respective layers 15. For example, seconddie half 16 may include a third layer 44 and a fourth layer 46 oppositethird layer 44, with third layer 44 cut to form a first portion 48 ofsecond die cavity 20, and fourth layer 46 cut to form a second portion50 of second die cavity 20. Third layer 44 and fourth layer 46 areconfigured to be stacked together such that first portion 48 of seconddie cavity 20 and second portion 50 of second die cavity 20 arepositioned with respect to one another to form second die cavity 20.Similar to first die half 14, second die half 16 may include just thirdlayer 44 and fourth layer 46, or may include one or more additional,intervening layers 36 positioned between third layer 44 and fourth layer46, with each respective intervening layer 36 forming a portion ofsecond die cavity 20.

FIG. 1 illustrates intervening layer 36 d, intervening layer 36 e, andintervening layer 36 f, though other examples of second die half 16 mayinclude more or fewer intervening layers 36 positioned between thirdlayer 44 and fourth layer 46. In some examples, second die half 16includes a single intervening layer 36 (e.g., layer 36 d) positionedbetween third layer 44 and fourth layer 46. In other examples, seconddie half 16 includes at least two intervening layers 36, at least threeintervening layers 36, at least four intervening layers 36, at leastfive intervening layers 36, at least six intervening layers 36, at leastseven intervening layers 36, at least eight intervening layers 36, atleast nine intervening layers 36, at least ten intervening layers 36, atleast 12 intervening layers 36, at least 15 intervening layers 36, atleast 20 intervening layers 36, and/or at least 25 intervening layers36. In yet other examples, more intervening layers 36 may be included.Second die half 16 of forging die 12 may be selectively customizable,such that the number of layers 15, the thickness of different respectivelayers 15, and/or the materials used to form different respective layers15 (or different respective second die halves 16) may be variabledepending on, for example, the geometry, contours, or other propertiesof the part to be forged. As with first die half 14, the number andthickness of respective layers of second die half 16 may be variedaccording to the part geometry to minimize the presence of thin platesections and/or small radii in the respective cut portions of therespective layers. In some examples, the number of layers 15 in firstdie half 14 and/or second die half 16 may be optimized for ease ofmanufacture of the respective die half and/or for cost efficiency. Insome examples, first die half 14 and/or second die half 16 may includelayers 15 of alternating thicknesses, such as to account for varyinggeometry or stress in a given layer 15.

Each intervening layer 36 of second die half 16 may be cut to form aportion of second die cavity 20. For example, intervening layer 36 d iscut to form a third portion 52 of second die cavity 20, interveninglayer 36 e is cut to form a fourth portion 54 of second die cavity 20,and intervening layer 36 f is cut to form a fifth portion 56 of seconddie cavity 20. In examples where second die half 16 includes second diecavity 20, second die half 16 and first die half 14 are configured tocooperate with one another such that first die cavity 18 faces seconddie cavity 20 and such that first die cavity 18 and second die cavity 20are each configured to receive a respective portion of preform 22. Inthis manner, forging die 12 is configured to forge a part from preform22 when first die half 14 and second die half 16 are pressed together.

A second plurality of fasteners 58 may be configured to fasten therespective layers of second die half 16 together. For example, secondplurality of fasteners 58 secures third layer 44, fourth layer 46, andany intervening layers 36 (e.g., layers 36 d, 36 e, and 36 f, each ofwhich are examples of layers 15) together to form second die half 16.Each respective fastener of second plurality of fasteners 58 may extendthrough some or all of one or more layers 15 of second die half 16, buttogether function to assemble and align layers 15 with respect to oneanother and to resist or prevent movement of respective layers 15 withrespect to one another, such that the respective layers 15 arepositioned with respect to one another to maintain the desired alignmentof cut portions, thereby forming second die cavity 20. Additionally oralternatively, respective layers of second die half 16 may be securedtogether by other suitable means, such as by using adhesives. Second diecavity 20 is generally shaped in accordance with the desired size,shape, and contours of the desired finished part to be forged in forgingdie 12, and is configured to receive at least a portion of preform 22.

In some systems 10, first die half 14 may include a first baseplate 60,and/or second die half 16 may include a second baseplate 62. Firstbaseplate 60, when included, may be secured to second layer 28, andsecond baseplate 62, when included, may be secured to fourth layer 46(or to an upper surface 64 opposite second engagement surface 34, inexamples where second die half 16 is not formed of multiple layers 15).Thus, when first die half 14 and second die half 16 are arranged withrespect to one another to forge a part (e.g., with first die cavity 18facing second die half 16), first baseplate 60 and second baseplate 62may be positioned opposite one another, with the respective layers 15 offirst die half 14 and the respective layers 15 of second die half 16positioned between the two baseplates 60, 62. First baseplate 60 may bethicker than any layer 15 of first die half 14. Similarly, secondbaseplate 62 may be thicker than any layer 15 of second die half 16.First baseplate 60 and second baseplate 62 may be substantially solidplates, such that they do not form a portion of first die cavity 18 orsecond die cavity 20, respectively. First baseplate 60 may be configuredto support and/or strengthen first die half 14 and/or to reduce thenumber of layer interfaces (e.g., reduce the number of layers 15) offirst die half 14. Similarly, second baseplate 62 may be configured tosupport and/or strengthen second die half 16 and/or to reduce the numberof layer interfaces of second die half 16. In some examples, firstbaseplate 60 and/or second baseplate 62 may be shared amongst multipledie sets, which may decrease costs and/or increase efficiency in makingdisclosed forging dies 12.

In some specific examples, first layer 24 is thicker than second layer28 of first die half 14. For example, first layer 24 may be at leasttwice as thick as second layer 28. Similarly, third layer 44 is thickerthan fourth layer 46 of second die half 16, in some examples. Forexample, third layer 44 may be at least twice as thick as fourth layer46. First layer 24 of first die half 14 and third layer 44 of second diehalf 16 generally represent the center-most layers of forging die 12,adjacent where first die half 14 and second die half 16 are engaged withone another during forging. In some examples, first layer 24 forms alarger respective portion of first die cavity 18 than other layers 15 offirst die half 14 (e.g., first portion 26 of first die cavity 18 may belarger than the other respective portions cut from the other respectivelayers 15 of first die cavity 18). Similarly, third layer 44 forms alarger respective portion of second die cavity 20 than other layers 15of second die cavity 20 in some examples (e.g., first portion 48 ofsecond die cavity 20 may be larger than the other respective portionscut from the other respective layers 15 of second die cavity 20).Accordingly, first layer 24 and third layer 44 may be thicker than otherrespective layers 15 to account for additional stresses that may beexperienced in the first and third layers of first die half 14 andsecond die half 16, respectively. In some examples, first baseplate 60is thicker than any other layer of first die half 14, such as being atleast twice as thick as any other layer 15. Similarly, second baseplate62 may be thicker than any other layer of second die half 16, such asbeing at least twice as thick as any other layer 15. In one specificexample, first layer 24 and third layer 44 may each be between 20-40 mmthick, second layer 28 and fourth layer 46 may each be between 10-20 mmthick, and first baseplate 60 and second baseplate 62 may each bebetween 50-90 mm thick.

Layers 15 generally are configured to be cut before being stacked andfastened together to form respective die halves 14, 16. For example,each of first layer 24, second layer 28, third layer 44, fourth layer46, and/or any intervening layer 36 may be configured to be water jetcut in order to form first die cavity 18 and/or second die cavity 20,respectively. Said layers 15 may be cut to form sections of the diecavities using any suitable technique, including but not limited tolaser cutting, water jet cutting, band saw (or other saw) cutting,machining, milling, and/or plasma cutting.

First plurality of fasteners 32 and second plurality of fasteners 58 maybe any suitable fasteners, and may be configured to be selectivelyremovable, such that one or more layers 15 may be removable from arespective die half. In some examples, first plurality of fasteners 32includes a plurality of bolts securing the layers of first die half 14together, and second plurality of fasteners 58 likewise may include aplurality of bolts securing the layers of second die half 16 together.In other examples, fasteners 32, 58 may include screws, nuts, rivets,inserts, clamps, clips, brackets, nails, posts, studs, anchors, and/orany other suitable fastener. Each respective fastener of first pluralityof fasteners 32 may extend through at least a portion of one or morelayers of first die half 14. In some examples, at least some respectivefasteners of first plurality of fasteners 32 extend through all thelayers of first die half 14. In some examples, at least some respectivefasteners of first plurality of fasteners 32 extend through just some ofthe layers of first die half 14, such as through at least two respectivelayers 15 of first die half 14. Similarly, each respective fastener ofsecond plurality of fasteners 58 may extend through at least a portionof one or more layers 15 of second die half 16. In some examples, atleast some respective fasteners of second plurality of fasteners 58extend through all the layers of second die half 16. In some examples,at least some respective fasteners of second plurality of fasteners 58extend through just some of the layers of second die half 16, such asthrough at least two respective layers of second die half 16.

In some examples, each fastener of first plurality of fasteners 32 isspaced apart from first die cavity 18, such that fasteners 32 do notenter first die cavity 18. Similarly, in some examples, each fastener ofsecond plurality of fasteners 58 is spaced apart from second die cavity20, such that fasteners 58 do not enter second die cavity 20. Fasteners32 may be configured such that when the layers 15 of first die half 14are assembled and secured together, adjacent respective layers 15 are incontact with one another. Similarly, fasteners 58 may be configured suchthat when the layers 15 of second die half 16 are assembled and securedtogether, adjacent respective layers 15 are in contact with one another.In some examples, each respective layer 15 is selectively removable fromfirst die half 14 by removing one or more of the fasteners 32, and eachrespective layer 15 is selectively removable from second die half 16 byremoving one or more of the fasteners 58. In this manner, if a givenlayer 15 is worn or in need of replacement (e.g., due to wear occurringduring forging, transport, or otherwise), the worn layer may beselectively removed from the assembled first die half 14 or second diehalf 16, and replaced with a new layer that has been cut to form thesame respective portion of the respective die cavity as the removedlayer. In this manner, forging dies 12 according to the presentdisclosure may be easier to maintain and repair than conventionalforging dies, because repairs may be carried out by replacing individuallayers rather than needing to replace an entire die half.

Different respective layers 15 of forging die 12 may be formed ofdifferent materials from other respective layers 15, in some examples.For example, at least one of first layer 24, second layer 28, thirdlayer 44, fourth layer 46, first baseplate 60, second baseplate 62,and/or any additional layer 36 of first die half 14 and/or second diehalf 16 may be formed of a different material or grade of material thanat least one other of first layer 24, second layer 28, third layer 44,fourth layer 46, first baseplate 60, second baseplate 62, and/or anyadditional layer 36 of first die half 14 and/or second die half 16. Insome examples, first layer 24 is formed of a different material ordifferent grade of material than is second layer 28 and/or anyintervening layers 36 of first die half 14. For example, first layer 24may be thicker than second layer 28 and/or additional layers 36 of firstdie half 14. Additionally or alternatively, first layer 24 may be formedof a stronger material than second layer 28 and other layers 36 of firstdie half 14. In one specific example, first layer 24 may be formed oftool steel, while second layer 28 and any intervening layers 36 of firstdie half 14 may be formed of strip steel, or another material or gradeof steel. “Tool steel” refers to a variety of carbon and alloy steelsthat are configured for use in the manufacture of tools. For example,suitable tool steel materials may have a distinctive hardness,resistance to abrasion and deformation, and/or a distinctive ability tohold a cutting edge at elevated temperatures. In some examples, toolsteel has a carbon content of between 0.5% and 1.5%. Tool steels mayalso include tungsten, chromium, vanadium, and/or molybdenum. As usedherein, a material is considered stronger than another material if thestronger material is more wear-resistant, has a higher hardness, has ahigher tensile and/or compression strength, and/or has a highertoughness than the other material. In some examples, a higher strengthmaterial may be used for a particular respective layer 15 (or multiplerespective layers 15) to add strength to forging die 12 without needingto use the higher strength material at every layer. Additionally oralternatively, a higher strength material may be used for one or morerespective layers 15, while a higher ductile material may be used forone or more other respective layers 15, thereby providing forging die 12with good overall strength and ductility of the die. In some examples,different respective layers 15 may be configured to be moreoxidation-resistant than other respective layers 15.

Similarly, in some examples, third layer 44 is formed of a differentmaterial or different grade of material than is fourth layer 46 and/orany intervening layers 36 of second die half 16. For example, thirdlayer 44 may be formed of a stronger material than fourth layer 46 andother layers 36 of second die half 16. In one specific example, thirdlayer 44 may be formed of tool steel, while fourth layer 46 and anyintervening layers 36 of second die half 16 may be formed of stripsteel, or a different material or grade of steel. Additionally oralternatively, third layer 44 may be thicker than fourth layer 46 and/oradditional layers 36 of second die half 16.

In some examples, forging die 12 may include one or more sensors 66encapsulated in first die half 14 and/or one or more sensors 66encapsulated in second die half 16. For example, sensors 66 may beconfigured to monitor and/or measure data from first die half 14 and/orsecond die half 16 during forging of the part, and/or during heating offorging die 12. For example, sensors 66 may be configured to measure atemperature of first die half 14, a temperature of second die half 16, atemperature of the part being forged, and or the amount of forginglubricant within forging die 12.

Some examples of forging die 12 include one or more cooling channels 68and/or one or more heating channels 70. Cooling channels 68 may beformed in first die half 14 and/or second die half 16, and may extendthrough one or more respective layers 15 of the die half. Coolingchannels 68 may be configured to deliver a cooling fluid to differentinternal locations within first die half 14 and/or second die half 16,thereby cooling first die half 14, second die half 16, and/or anypreform 22 or part located within first die cavity 18 and/or second diecavity 20. Similarly, heating channels 70 may be formed in first diehalf 14 and/or second die half 16, and may extend through one or morerespective layers 15 of the die half. Heating channels 70 may beconfigured to deliver a heating fluid to different internal locationswithin first die half 14 and/or second die half 16, thereby heatingfirst die half 14, second die half 16, and/or any preform 22 or partlocated within first die cavity 18 and/or second die cavity 20. In someexamples, the same channel may serve as both a heating channel 70 and acooling channel 68. For example, a channel may deliver cooling fluid toforging die 12 during a first period of time during the forging process,and may deliver heating fluid to forging die 12 during a second periodof time during the forging process. Additionally or alternatively,cooling channels 68 and/or heating channels 70 may be used to provideprotective atmospheric gases and/or lubricant to forging die 12.Additionally or alternatively, heating elements, such as electriccartridge heaters, may be positioned within cooling channels 68 and/orheating channels 70 to heat forging die 12.

Forging dies 12 may include one or more slots 72 formed in first diehalf 14 and/or second die half 16. Such slots 72 may house a straingauge configured to monitor and/or measure strain within one or morelayers 15 of first die half 14 and/or within one or more layers 15 ofsecond die half 16. Additionally or alternatively, forging dies 12 mayinclude drafts and/or fillets incorporated into first die half 14 and/orsecond die half 16, wherein the drafts and/or fillets are configured tofacilitate removal of the part from first die half 14 and/or second diehalf 16 after forging. In some examples. Additionally or alternatively,such drafts and/or fillets may be configured to facilitate metal flowwithin first die cavity 18 and/or second die cavity 20 during forging.Forging dies 12 according to the present disclosure may be used to makeforgings that are close-to-finished forgings in some examples.Additionally or alternatively, forging dies 12 may be used to makeforgings that pre-shape a raw material, and/or forgings (e.g., parts)having drafts or fillets that are intended to be further machined afterforging, to create the final part. In some examples, a series of blockerand finishing dies may be used, which may be made according to methodsof the present disclosure, or may be made according to conventionalmethods.

Additionally or alternatively, forging dies 12 may include one or morereinforcement elements (also referred to herein as reinforcing elements,or reinforcing bars) configured to strengthen the respective die halvesand/or to resist movement of respective layers 15 relative to oneanother within a given die half 14, 16. For example, first die half 14may include a first reinforcing element 74, which may be secured to afirst outer surface 78 of first die half 14 and/or to first baseplate60. In some examples, first outer surface 78 is the outer surface ofsecond layer 28. Additionally or alternatively, second die half 16 mayinclude a second reinforcing element 76, which may be secured to uppersurface 64 of second die half 16 and/or to second baseplate 62.Reinforcing elements 74, 76 may be welded to respective die halves 14,16, or may be secured to the die halves in any other suitable manner. Insome examples, reinforcing elements 74, 76 may take the form of a squarebar, though they are not limited to such.

Forging die 12 may be used to form various different parts, such asmetallic parts, glass parts, composite parts, ceramic parts, and/orplastic parts. In some examples, layered dies may be made according tothe present disclosure for use in compression molding for composites orplastics, or for forming dies for glass or ceramics. In some cases,parts forged in presently disclosed forging dies may be large parts,such as having a length or radius of at least 1 foot. Forged parts maybe used in many different applications, including but not limited toparts for aircraft, vehicles, big frame production, and/or marine craft.Any suitable preform 22 may be used with forging die 12, such asbillets, bars, blanks, ingots, blooms, slabs or other semi-finishedcasting products. Preform 22 may be formed of any suitable material,including but not limited to metals, metal alloys, ceramics, andplastics.

In use, at least a portion of a preform 22 is positioned within firstdie cavity 18 and/or second die cavity 20, and first die half 14 andsecond die half 16 are then engaged with one another such that they arebrought together (e.g., along arrow 25) and pressed together, therebyforcing preform 22 to be shaped according to the shape of first diecavity 18 and/or second die cavity 20. During forging, excess materialof preform 22 may be forced away from the preform. Forging die 12 may beconfigured to substantially prevent such excess material from getting inbetween respective layers of first die half 14 or second die half 16.For example, first die half 14 may include enough fasteners 32 that arepositioned sufficiently to prevent introduction of excess material frompreform 22 into spaces or areas between adjacent respective layers 15 offirst die half 14 during forging of the part. First fasteners 32 mayalso be configured to substantially prevent movement (e.g., lateralsliding) of respective adjacent layers 15 of first die half 14 withrespect to one another during forging. In this manner, first fasteners32 may be configured to maintain integrity of first die half 14 duringforging of the part. In some examples, first die half 14 may include atleast five, at least ten, at least fifteen, at least twenty, at leastthirty, at least forty, and/or at least fifty fasteners 32. In somespecific examples, first fasteners 32 may be M20 screws, though anysuitable fastener may be used for first fasteners 32. In some examples,first fasteners 32 may include one or more keyways configured to preventrespective layers 15 from sliding or laterally moving with respect toone another.

Similarly, second die half 16 may include a plurality of fasteners 58that are positioned sufficiently to prevent introduction of excessmaterial from preform 22 into spaces or areas between adjacentrespective layers 15 of second die half 16 during forging of the part.Second fasteners 58 may also be configured to substantially preventmovement (e.g., lateral sliding) of respective adjacent layers 15 ofsecond die half 16 with respect to one another during forging. In thismanner, second fasteners 58 may be configured to maintain integrity ofsecond die half 16 during forging of the part. In some examples, seconddie half 16 may include at least five, at least ten, at least fifteen,at least twenty, at least thirty, at least forty, and/or at least fiftyfasteners 58. In some specific examples, second fasteners 58 may be M20screws, though any suitable fastener may be used for second fasteners58. In some examples, second fasteners 58 may include one or morekeyways configured to prevent respective layers 15 from sliding orlaterally moving with respect to one another.

When forging a part in forging die 12, first die half 14 and second diehalf 16 may be loaded into a forging press 77 that is configured topress the die halves 14, 16 together and apply pressure to the diehalves, thereby forging the part within first die cavity 18 and/orsecond die cavity 20. Forging press 77 may be any suitable type ofpress, though in some examples is a hydraulic press. In some examples,forging press 77 is configured to have a ram velocity of at least 5 mm/sand exert at least 50 MegaPascal (MPa) of force onto forging die 12.While not limited to the same, in some examples, forging press 77 isconfigured to exert a force of between 55-1,000 MPa (80-140 kilopoundsper square inch (KSI)) on forging die 12. Some systems 10 include afurnace 80 and/or other heating element configured to heat preform 22and/or forging die 12 before and/or during forging the part. In someexamples, the first use of forging die 12 results in deformation offirst layer 24 and/or third layer 44 such that a first perimeter ridge71 is formed around a first perimeter 79 (FIG. 2) of first die cavity 18and/or such that a second perimeter ridge 73 is formed around a secondperimeter 81 (FIG. 2) of second die cavity 20. Additionally oralternatively, the first use of forging die 12 may result in adeformation in the form of displacement of first layer 24 and/or firstportion 26 of first die cavity 18 with respect to an adjacent respectivelayer 15, and/or displacement of third layer 44 and/or first portion 48of second die cavity 20 with respect to an adjacent respective layer.

Once forging is complete, the resulting forged part is removed fromforging die 12, such as by separating first die half 14 and second diehalf 16. In some examples, first die half 14 and second die half 16 areseparated by moving one respective die half away from the other diehalf, or by moving both die halves away from each other. In otherexamples, first die half 14 and second die half 16 may be hingedtogether, such that separating the die halves may be accomplished bypivoting one or both die halves away from the other.

Disclosed forging dies 12 may facilitate the manufacture of such forgingdies more rapidly than conventional forging dies may be made. Forexample, because each respective layer 15 being cut is generallyrelatively thin as compared to the overall thickness of the die half,each layer 15 may be cut faster than would be typical for machining adie cavity into a solid block of material. Disclosed methods of makingsuch forging dies may enable new forging dies to be easily made for oldparts. In some examples, forging dies 12 are used to make a relativelylow number of parts and then may be treated as disposable, due to thelow cost and time consumption for making disclosed forging dies 12, ascompared to conventional forging dies.

Turning now to FIGS. 2-12, illustrative non-exclusive examples offorging dies 12, layers 15 for forming forging dies 12, preforms 22, andforged parts are illustrated. Where appropriate, the reference numeralsfrom the schematic illustration of FIG. 1 are used to designatecorresponding parts in FIGS. 2-12; however, the examples of FIGS. 2-12are non-exclusive and do not limit forging dies 12, layers 15 forforming forging dies 12, preforms 22, or forged parts to the illustratedembodiments of FIGS. 2-12. That is, forging dies 12, layers 15 forforming forging dies 12, preforms 22, and forged parts are not limitedto the specific embodiments illustrated and may incorporate any numberof the various aspects, configurations, characteristics, properties,etc. that are illustrated in and discussed with reference to theschematic representation of FIG. 1 and/or the embodiments of FIGS. 2-12,as well as variations thereof, without requiring the inclusion of allsuch aspects, configurations, characteristics, properties, etc. For thepurpose of brevity, each previously discussed component, part, portion,aspect, region, etc. or variants thereof may not be discussed,illustrated, and/or labeled again in each of FIGS. 2-12; however, it iswithin the scope of the present disclosure that the previously discussedfeatures, variants, etc. may be utilized with these embodiments.

FIG. 2 illustrates a forging die 82, which is an example of forging die12, before or after being used to forget a part. Forging die 82 includesa first die half 84 (which is an example of first die half 14) and asecond die half 86 (which is an example of second die half 16). Firstdie half 84 includes first die cavity 18 that extends through aplurality of layers 15 that are stacked as shown to form first die half84. In this example, first layer 24 is positioned on top of the otherrespective layers of first die half 84, and thus first engagementsurface 35 of first layer 24 faces second die half 86 when the two diehalves are engaged with one another to forge a part. As shown in FIG. 2,a portion (e.g., first perimeter ridge 71) of first engagement surface35 may be raised with respect to the rest of first engagement surface35, such as in areas adjacent first perimeter 79 of first die cavity 18.First die half 84 also includes second layer 28 and four interveninglayers 36 positioned between first layer 24 and second layer 28. Firstbaseplate 60 is secured to second layer 28 in this example. A pluralityof fasteners 32 are positioned around first die cavity 18 to securelayers 15 together and with respect to one another, to form first diehalf 84. More or fewer fasteners 32 may be included in variations ofthis example. Similarly, more or fewer intervening layers 36 may beincluded in different variations. In the example of FIG. 2, all oflayers 15 are of a substantially uniform thickness (other than portionsof the respective layers that are cut to form first die cavity 18), withfirst baseplate 60 being thicker than each respective layer 15 of firstdie half 84, though in other examples, layers 15 are of varyingthicknesses.

In the example of FIG. 2, second die half 86 is essentially a mirrorimage of first die half 84, with second die half 86 including thirdlayer 44 and fourth layer 46, with four intervening layers 36 positionedtherebetween. Second baseplate 62 is secured to fourth layer 46, and aplurality of fasteners 58 are positioned around second die cavity 20 tosecure layers 15 of second die half 86 together and with respect to oneanother. Third layer 44 includes second engagement surface 34, whichfaces first die half 84 when the two die halves are engaged with oneanother. As shown in FIG. 2, a portion (e.g., second perimeter ridge 73)of second engagement surface 34 may be raised with respect to the restof second engagement surface 34, such as in areas adjacent secondperimeter 81 of second die cavity 20. When first die half 84 and seconddie half 86 are engaged with one another, first die cavity 18 and seconddie cavity 20 are aligned with one another such that the desired part isforged in forging die 82 when the die halves are pressed together. Inother examples, second die half 86 may be arranged differently, suchthat it is not a mirror image of first die half 84 (e.g., forging die 82may be asymmetrical). In use, a preform (e.g., preform 22) is positionedwithin first die cavity 18 and/or second die cavity 20, and then firstdie half 84 and second die half 86 are brought together to engage withone another, such that a portion of the preform is positioned in each offirst die cavity 18 and second die cavity 20. Accordingly, when forgingdie 82 is pressed together, the preform is shaped according to the diecavities.

FIGS. 3-5 illustrate representative examples of suitable preforms 22,though suitable preforms are not limited to these examples, and may takea variety of shapes and sizes, with suitable preforms being selecteddepending on the geometry of the part to be forged. FIG. 3 illustrates acylindrical preform 88. FIG. 4 illustrates an elongated preform 90having an oval-shaped cross-sectional area. FIG. 5 illustrates a billet92 that is substantially cylindrical, but that includes a first, largerdiameter portion 94, and a second, smaller diameter portion 96. In otherexamples, preforms may have a substantially rectangular, square,polygonal, and/or irregular cross-sectional area. In some examples,preform 22 may be tapered and/or include fillets. In some examples, thepreform geometry may be selected based on press load, where the preformgeometry resulting in the lowest stresses in the forging die duringforging is used to forge the part. FIG. 6 illustrates a representativepart 98 that may be forged in presently disclosed forging dies, with thepart 98 having features resulting from the shape of first die cavity 18and second die cavity 20 of the forging die used to make part 98.

FIG. 7 illustrates a cut-away view of a portion of first die half 84from FIG. 2, showing variations in how each layer 15 is cut to formfirst die cavity 18. As shown in FIG. 7, each layer 15 may be cut toform first die cavity 18, with the respective layers being positionedwith respect to one another such that the cut portions are aligned toform first die cavity 18 when the layers are stacked and assembledtogether. First baseplate 60 is not cut to form a portion of first diecavity 18. A plurality of holes 100 are formed through first die half84, as shown, for receiving fasteners 32 such that fasteners 32 securethe layers 15 of first die half 84 together. As shown in FIG. 7, holes100 may extend through the entire first die half 84 (including throughfirst baseplate 60), in some examples. Holes 100 are positioned so asnot to interfere with first die cavity 18.

FIG. 8 illustrates an exploded, cut-away view of a forging die 102,which is an example of forging die 12. A first die half 104 (which is anexample of first die half 14) is configured to be engaged with a seconddie half 106 (which is an example of second die half 16) such that firstdie cavity 18 and second die cavity 20 are aligned with one another andfacing one another to forge a part therein, such as from preform 22.Forging die 12 and preform 22 are shown in cut-away such that first diecavity 18 and second die cavity 20 are visible, though generally the diecavities are spaced away from the outer edges of the die halves, as bestseen in FIG. 2. In this example, first die half 104 is formed from aplurality of layers that are described herein, while second die half 106is formed of a single layer having second die cavity 20 formed therein.In other examples, second die half 106 may be formed of a single layerof material and/or may not include second die cavity 20, such thatsubstantially all of preform 22 is positioned within first die cavity 18during forging. Forging die 102 may include one or more alignment pinsor other alignment structures to facilitate alignment of first die half104 with respect to second die half 106 (e.g., to facilitate alignmentof first die cavity 18 and second die cavity 20).

FIG. 9 illustrates an exploded, cutaway view of first die half 104 ofFIG. 8, with the layers 15 shown separated from one another forillustration purposes. First die half 104 is shown cut-away such thatessentially half of first die half 104 is not shown, in order to moreclearly illustrate the different sections of first die cavity 18 and howthe layers 15 of first die half 104 together form the cavity. Each offirst layer 24, second layer 28, intervening layer 36 a, interveninglayer 36 b, intervening layer 36 c, and intervening layer 36 d is cut toform a respective portion of first die cavity 18. For example, firstlayer 24 is cut to form a first portion 108 of first die cavity 18,second layer 28 is cut to form a second portion 110 of first die cavity18, intervening layer 36 a is cut to form a third portion 112 of firstdie cavity 18, intervening layer 36 b is cut to form a fourth portion114 of first die cavity 18, intervening layer 36 c is cut to form afifth portion 116 of first die cavity 18, and intervening layer 36 d iscut to form a sixth portion 118 of first die cavity 18. When layers 15of first die half 104 are stacked in the prescribed order, therespective portions cut into the respective layers align to form thedesired first die cavity 18.

A selection of respective layers 15 of first die half 104 areillustrated separately, for clarity. FIG. 10 shows first layer 24 offirst die half 104 and first portion 108 of first die cavity 18 formedtherein. FIG. 11 shows intervening layer 36 a and third portion 112 offirst die cavity 18. FIG. 12 shows intervening layer 36 c and fifthportion 116 of first die cavity 18. As illustrated, in this example,each respective portion of first die cavity 18 is unique, such that eachrespective layer 15 is distinct from one another. Layers 15 are thusstacked in a particular order to form first die half 104, such that thecut portions are arranged with respect to one another to create firstdie cavity 18. In other examples, one or more layers of a given die halfmay be substantially identical to one another.

FIGS. 13-14 schematically provide flowcharts that representillustrative, non-exclusive examples of methods according to the presentdisclosure. In FIGS. 13-14, some steps are illustrated in dashed boxesindicating that such steps may be optional or may correspond to anoptional version of a method according to the present disclosure. Thatsaid, not all methods according to the present disclosure are requiredto include the steps illustrated in solid boxes. The methods and stepsillustrated in FIGS. 13-14 are not limiting and other methods and stepsare within the scope of the present disclosure, including methods havinggreater than or fewer than the number of steps illustrated, asunderstood from the discussions herein.

FIG. 13 illustrates methods 200 of making a forging die (e.g., forgingdie 12) for forging a part from a preform (e.g., preform 22), such as abar, a blank, and/or a billet. Methods 200 generally include forming afirst die half (e.g., first die half 14) at 202, and engaging the firstdie half with a second die half (e.g., second die half 16) at 204, suchthat a first die cavity (e.g., first die cavity 18) faces the second diehalf (and/or a second die cavity of the second die half, such as seconddie cavity 20). Forming the first die half at 202 generally includescutting a first layer (e.g., first layer 24) to form a first portion ofthe first die cavity (e.g., first portion 26) at 206, cutting a secondlayer (e.g., second layer 28) to form a second portion of the first diecavity (e.g., second portion 30) at 208, stacking the first layer andthe second layer together at 210, and fastening the first layer and thesecond layer together at 212. Stacking the first layer and the secondlayer together at 210 includes positioning the first layer with respectto the second layer to form an assembly or laminate, such that the firstand second portions are positioned with respect to one another to formthe first die cavity. Fastening the first and second layers together at212 may include fastening the layers together (e.g., via first pluralityof fasteners 32) and/or otherwise binding them together, such as via anadhesive or other fastening means. In some examples, fastening the firstand second layers together at 212 may include inserting one or morekeyways into the forging die to maintain alignment of the layers of theforging die. Additionally or alternatively, stacking the first andsecond layer together at 210 and/or fastening the first and secondlayers at 212 may include dressing one or more interfaces betweenlayers, to create smooth, continuous layer interfaces and/or diecavities.

In some methods 200, forming the first die half at 202 includes cuttingone or more additional layers (e.g., one or more intervening layers 36)at 214. In these examples, each additional layer is cut to form arespective portion of the first die cavity, and the stacking the layersat 210 includes stacking the additional layers between the first layerand the second layer such that the cut portions are aligned and thelayers are arranged in the appropriate order to form the desired firstdie cavity. Fastening the layers at 212 may include selectively andremovably fastening (e.g., bolting) the layers together such that anyrespective layer may be removed from the assembled first die half byremoving one or more of the fasteners. In such methods, a worn layer maybe removed and replaced with a replacement layer for maintenance of thefirst die half, without needing to replace the entire die half.

The cutting the first layer at 206, the cutting the second layer at 208,and the cutting any additional layers at 214 generally are performedprior to the fastening the layers together at 212 and prior to thestacking the layers at 210. In this manner, each respective layer may becut individually, which may reduce wear on cutting tools during themaking of the disclosed forging dies, as compared to conventionalforging dies formed from solid blocks of material. Cutting the layers at206, 208, and/or 214 is generally performed via water cutting, thoughany cutting technique is within the scope of the present disclosure,such as laser cutting, band saw (or any saw) cutting, machining,milling, and/or plasma cutting. Methods 200 of making presentlydisclosed forging dies may be configured to be performed more quickly oreasily than conventional methods of forming forging dies, as presentlydisclosed methods 200 generally do not include needing to shape theplates with machine contoured surfaces; it is simply a matter of cuttingthe die cavity into each respective layer.

In some methods 200, the second die half may be a solid and/or flat diehalf, such that the first die cavity in the first die half receivessubstantially the entire preform (e.g., the first die cavity isessentially sized and shaped according to the entire desired part to beforged). In other methods, the first die cavity in the first die halfmay receive just a portion of the preform, and the second die half mayinclude a second die cavity (e.g., second die cavity 20), where thefirst die cavity and the second die cavity together receive the preformand form the forged part. Such methods 200 may include forming a seconddie half at 216, which may mirror the forming the first die half at 202.For example, forming the second die half at 216 generally includescutting a third layer (e.g., third layer 44) of the second die half toform a first portion of the second die cavity (e.g., first portion 48)at 218 and cutting a fourth layer (e.g., fourth layer 46) of the seconddie half to form a second portion of the second die cavity (e.g., secondportion 50) at 220.

Forming the second die half at 216 may also include stacking the thirdand fourth layers together at 222 such that the first and secondportions of the second die cavity are positioned with respect to oneanother and aligned to form the second die cavity (e.g., thereby formingan assembly or laminate), and fastening the third and fourth layerstogether at 224 to assemble the second die half. Fastening the third andfourth layers together at 224 may include fastening the layers together(e.g., via second plurality of fasteners 58) and/or otherwise bindingthem together, such as via an adhesive or other fastening means. In someexamples, fastening the third and fourth layers together at 224 mayinclude inserting one or more keyways into the forging die to maintainalignment of the layers of the forging die. Additionally oralternatively, stacking the third and fourth layer together at 222and/or fastening the third and fourth layers at 224 may include dressingone or more interfaces between layers, to create smooth, continuouslayer interfaces and/or die cavities.

Again, some methods 200 include cutting one or more additional layers(e.g., one or more intervening layers 36) at 226. In these examples,each additional layer is cut to form a respective portion of the seconddie cavity, and the stacking the layers at 222 includes stacking theadditional layers between the third layer and the fourth layer such thatthe cut portions are aligned and the layers are arranged in theappropriate order to form the desired second die cavity. Fastening thelayers at 224 may include selectively and removably fastening (e.g.,bolting) the layers together such that any respective layer may beremoved from the assembled second die half by removing one or more ofthe fasteners. In such methods, a worn layer may be removed and replacedwith a replacement layer for maintenance of the second die half, withoutneeding to replace the entire die half. The cutting the third layer at218, the cutting the fourth layer at 220, and the cutting any additionallayers at 226 generally are performed prior to the fastening the layerstogether at 224 and prior to the stacking the layers at 222. Cutting thelayers at 218, 220, and/or 226 is generally performed via water cutting,though any cutting technique is within the scope of the presentdisclosure, such as laser cutting, machining, milling, band saw (or anytype of saw) cutting, and/or plasma cutting.

In some methods 200, forming the first die half at 202 includes securinga first baseplate (e.g., first baseplate 60) to the first layer or thesecond layer of the first die half at 228. Additionally oralternatively, forming the second die half at 216 may include securing asecond baseplate (e.g., second baseplate 62) to the third layer or thefourth layer of the second die half at 230. Such baseplates may besecured at 228 and/or 230 such that they strengthen the respective diehalf to which they are secured, though the baseplates generally are notcut to form a portion of the die cavities. In methods 200 includingsecuring one or more baseplates to the forging die at 228 and/or 230,engaging the first die half and the second die half at 204 may includepositioning the first die half and the second die half such that thefirst baseplate and the second baseplate are opposite one another, withthe first die cavity and/or the second die cavity positionedtherebetween.

Additionally or alternatively, methods 200 may include securing one ormore reinforcing elements at 232 and/or 234. For example, methods 200may include securing a first reinforcing element (e.g., firstreinforcing element 74) to the first die half at 232 and/or securing asecond reinforcing element (e.g., second reinforcing element 76) to thesecond die half at 234. In some methods, securing the first reinforcingelement at 232 and/or securing the second reinforcing element at 234 mayinclude welding the respective reinforcing element to the respective diehalf. Securing the first reinforcing element at 232 may include securingthe first reinforcing element to the first baseplate of the first diehalf, and/or securing the first reinforcing element to an outer surface(e.g., first outer surface 78) of the first die half. Similarly,securing the second reinforcing element at 234 may include securing thesecond reinforcing element to the second baseplate of the second diehalf, and/or securing the second reinforcing element to an outer surfaceof the second die half (e.g., upper surface 64). Reinforcing elementsmay be secured at 232, 234 by welding, fastening, adhering, or any othersuitable technique, such that they strengthen the first die half and/orsecond die half. In some examples, reinforcing elements may beconfigured to maintain the integrity of the first die half and/or seconddie half during forging.

Some methods 200 include determining the desired number of layers,thickness of layers, and/or material of layers for the first die halfand/or second die half at 236. Such determining at 236 may includeanalyzing the geometry and/or contours of a given part to be forged inthe forging die to determine the number of layers, thickness of layers,and/or material of layers to accommodate loads and stresses duringforging of the part. In some examples, different respective layers ofeach die half may have different respective thicknesses and/or may beformed of different materials from other respective layers of the diehalf, as described above. Additionally or alternatively, methods 200 mayinclude determining the desired number of fasteners, size of fasteners,and/or placement of fasteners at 238 for the first die half and/or thesecond die half. Such fasteners may be determined at 238 to apply asufficient compressive force to hold the respective layers of arespective die half together such that the die half retains itsintegrity during forging of the part. For example, the number, size,and/or placement of fasteners may be determined at 238 to prevent orresist lateral sliding movement of the layers with respect to oneanother during forging, and/or to prevent or resist introduction ofmaterial from the preform into spaces between adjacent respective layersduring forging.

In some methods, forming the first die half at 202 may includeencapsulating one or more sensors (e.g., sensor 66) in the first diehalf at 240 and/or forming one or more heating channels (e.g., heatingchannel 70) and/or cooling channels (e.g., cooling channel 68) at 242.Similarly, forming the second die half at 216 may include encapsulatingone or more sensors in the second die half at 244 and/or forming one ormore heating channels and/or cooling channels in the second die half at246. Additionally or alternatively, forming the first die half at 202may include forming one or more slots (e.g., slot 72) in the first diehalf and positioning a strain gauge therein at 248, and/or forming thesecond die half at 216 may include forming one or more slots in thesecond die half and positioning a strain gauge therein at 250.Accordingly, some methods 200 may facilitate monitoring strain withinone or more layers of the first die half and/or within one or morelayers of the second die half during forging. Such monitoring may enableidentification of specific respective layers of the first die halfand/or second die half that may warrant removal and replacement due topossible wear.

In some methods 200, forming the first die half at 202 includes coatingone or more layers of the first die half at 252, and/or forming thesecond die half at 216 may include coating one or more layers of thesecond die half at 254. Such coating at 252 and/or 254 may includecoating one or more layers with a metallic and/or ceramic coatingconfigured to lubricate and/or prevent wear on the layers of therespective die half. Such coating at 252 and/or 254 may be applied byany coating technique, including but not limited to flame spraying,plasma spraying, forming a metal skin, diffusion bonding and/or brazing.In some specific examples, coating at 252 and/or 254 may include coatingone or more layers with a solution of graphite suspended in oil (e.g.,Houghton International Thermex Go/Fenella oil F G) or a water-basedproduct that may be free from graphite (e.g., Houghton ThermexWG/Fenella Fluid F G), which may be particularly useful for forgingaluminum alloy parts. In some specific examples, coating at 252 and/or254 may include coating one or more layers with Houghton InternationalThermex 8191 or a glass coating, such as may be useful for forgingtitanium, zirconium, and/or nickel alloy parts.

FIG. 14 illustrates methods 300 of making a part using presentlydisclosed forging dies 12. Methods 300 generally include providing aforging die (e.g., forging die 12) at 302, positioning a preform (e.g.,preform 22) within the forging die at 304, and pressing the first diehalf and the second die half of the forging die together (e.g., firstdie half 14 and second die half 16) at 306. In some methods 300,providing the forging die at 302 includes forming the first die half at202 (FIG. 13) and/or forming the second die half at 216 (FIG. 13).Positioning the preform within the forging die at 304 generally includespositioning at least a portion of the preform within a first die cavityof the first die half (e.g., first die cavity 18). In some examples,substantially the entire preform is positioned within the first diecavity. In some examples, a first portion of the preform is positionedwithin the first die cavity, and a second portion of the preform ispositioned within a second die cavity of the second die half (e.g.,second die cavity 20) when the first die half and the second die halfare engaged with one another. Pressing the first die half and the seconddie half together at 306 may include loading the forging die into aforging press (e.g., forging press 77) at 308 for pressing the diehalves together and forging the part.

Methods 300 may include heating the forging die and/or the preform(e.g., before positioning within the forging die, or while it ispositioned within the forging die) at 310, which may include heating theforging die and/or the preform to a minimum temperature of at least 100degrees C., at least 200 degrees C., at least 300 degrees C., at least400 degrees C., and/or at least 500 degrees C. After the die halves arepressed together at 306 for a sufficient amount of time and at asufficient force to shape the preform into the desired forged part, theresulting forged part is removed from the forging die at 312. Forexample, removing the part at 312 may include removing the forging diefrom the forging press and/or separating the first die half from thesecond die half to remove the forged part from the first die cavityand/or the second die cavity. Once the forged part is removed from theforging die, a new preform may be positioned within the forging die at304, and the forging die may again be pressed at 306 to form anotherforged part, which again may be removed from the forging die at 312. Thesequence may be repeated as many times as desired, to forge as manyparts as desired within the disclosed forging die. In some methods 300,the forging die is configured to produce a finished or close-to-finishedpart. In other methods 300, the forging die may be configured to producea part having drafts and/or fillets that are intended to be furthermachined after removal from the forging die, and thus in some examples,removing the part at 312 may include machining the part after removal,to finish the forged part.

Some methods 300 include monitoring the layers of the forging die at314. For example, monitoring the forging die at 314 may includemonitoring and/or measuring strain within the first die half and/or thesecond die half, such as by measuring and analyzing data from one ormore strain gauges positioned to monitor the forging die. Such straingauges may be embedded in one or more respective layers of the first diehalf and/or second die half, or may be otherwise positioned with respectto the forging die to monitor it. Additionally or alternatively,monitoring the forging die at 314 may include monitoring a temperatureof the part being forged and/or of the forging die, such as via one ormore sensors (e.g., sensors 66) that may be encapsulated within theforging die and/or otherwise secured to the forging die and/or otherwisepositioned within respect to the forging die to measure data. In somemethods, monitoring the forging die at 314 may be performed duringforging of the part at 306. Additionally or alternatively, monitoringthe forging die at 314 may include inspecting the forging die while notin use (e.g., between successive respective forgings) to identify areasof potential wear or excessive stress beyond a predetermined thresholdwithin the first die half and/or the second die half. Monitoring theforging die at 314 may be performed on one or more individual respectivelayers of the forging die, and/or on the entire forging die.

In some cases, the monitoring the forging die at 314 may result inidentification of one or more respective layers of the first die halfand/or one or more respective layers of the second die half that haveareas of potential wear or excessive stress. In these instances, theidentified respective layers may be removed from the respective diehalf, and replaced by inserting a replacement layer at 316 in the placeof the removed layer. The replacement layer is generally the same sizeand shape of the removed layer, and is cut to form the same respectiveportion of the same respective die cavity as was the removed layer. Forexample, if the first layer of the first die half (forming a firstportion of the first die cavity) is removed, then the replacement layerwill be cut to form the first portion of the first die cavity.Similarly, if the second layer of the first die half (forming a secondportion of the first die half) is removed, then the replacement layerwill be cut to form the second portion of the first die half, andinserted into the first die half in the same respective position as thesecond layer was removed from. Such replacement layers may be formed(e.g., cut) on demand in some methods 300, such that replacement layersare formed once they are needed. Additionally or alternatively, suchreplacement layers may be formed ahead of time, such that they arepre-cut and ready to be inserted into a respective forging die half whenneeded. For example, if one or more respective layers of a given forgingdie are known to experience more stress or potential wear than the otherrespective layers, then replacement layers for these layers may beprepared before forging to have on hand for convenience.

Methods 300 may include flowing a heating fluid and/or a cooling fluidinto the forging press at 318. For example, cooling fluid may be flowedinto one or more cooling channels (e.g., cooling channel 68) formed inthe first die half and/or into one or more cooling channels formed inthe second die half at 318, such as in response to temperature readingsduring monitoring the forging die at 314. Additionally or alternatively,heating fluid may be flowed into one or more heating channels (e.g.,heating channel 70) formed in the first die half and/or into one or moreheating channels formed in the second die half at 318, such as inresponse to temperature readings during monitoring the forging die at314. Any suitable heating fluid and/or cooling fluid may be used. In onespecific example, superheated water may be flowed through heatingchannels at 318 to heat the preform during forging and/or to heat theforging die. Additionally or alternatively, the forging die may includea gas ring around the forging die, with the gas ring being configured tomaintain a temperature of the forging die during forging, and/or theforging die may include one or more heating cartridges positioned inand/or around the forging die and configured to provide heat to theforging die.

Illustrative, non-exclusive examples of inventive subject matteraccording to the present disclosure are described in the followingenumerated paragraphs:

A1. A method of making a forging die for forging a part from a preform,the method comprising:

forming a first die half, wherein the forming the first die halfcomprises:

-   -   cutting a first layer to form a first portion of a first die        cavity;    -   cutting a second layer to form a second portion of the first die        cavity;    -   stacking the first layer and the second layer together such that        the first portion of the first die cavity and the second portion        of the first die cavity are positioned with respect to one        another to form the first die cavity; and    -   fastening the first layer and the second layer together to form        the first die half; and

engaging the first die half with a second die half such that the firstdie cavity faces the second die half, wherein the first die half isconfigured to receive at least a portion of the preform, and wherein theforging die is configured to forge the part from the preform when thefirst die half and the second die half are pressed together.

A1.1. The method of paragraph A1, wherein the cutting the first layerand the cutting the second layer are performed before the fastening thefirst layer and the second layer together.

A1.2. The method of paragraph A1 or A1.1, wherein the cutting the firstlayer and the cutting the second layer are performed before the stackingthe first layer and the second layer together.

A1.3. The method of any of paragraphs A1-A1.2, further comprising:

forming the second die half, wherein the forming the second die halfcomprises:

-   -   cutting a third layer to form a first portion of a second die        cavity;    -   cutting a fourth layer to form a second portion of the second        die cavity;    -   stacking the third layer and the fourth layer together such that        the first portion of the second die cavity and the second        portion of the second die cavity are positioned with respect to        one another to form the second die cavity; and    -   fastening the third layer and the fourth layer together to form        the second die half;

wherein the second die half and the first die half are configured tocooperate with one another such that the first die cavity faces thesecond die cavity and such that the first die cavity and the second diecavity are each configured to receive a respective portion of thepreform, and wherein the forging die is configured to forge the partfrom the preform when the first die half and the second die half arepressed together.

A1.4. The method of paragraph A1.3, wherein the cutting the third layerand the cutting the fourth layer are performed before the fastening thethird layer and the fourth layer together.

A1.5. The method of paragraph A1.3 or A1.4, wherein the cutting thethird layer and the cutting the fourth layer are performed before thestacking the third layer and the fourth layer together.

A2. The method of any of paragraphs A1-A1.5, wherein the forming thefirst die half comprises:

cutting one or more additional first die layers to form additionalrespective portions of the first die cavity;

stacking the additional first die layers between the first layer and thesecond layer such that the additional respective portions of the firstdie cavity are positioned with respect to the first portion of the firstdie cavity and the second portion of the first die cavity, to form thefirst die cavity; and

fastening the additional first die layers to the first layer and thesecond layer to form the first die half.

A2.1. The method of paragraph A2, wherein the fastening the additionalfirst die layers comprises bolting the additional first die layers tothe first layer and the second layer.

A3. The method of paragraph A2 or A2.1, wherein the cutting theadditional first die layers comprises cutting at least one additionalfirst die layer, at least two additional first die layers, at leastthree additional first die layers, at least four additional first dielayers, at least five additional first die layers, at least sixadditional first die layers, at least seven additional first die layers,at least eight additional first die layers, at least nine additionalfirst die layers, at least ten additional first die layers, at leastfifteen additional first die layers, at least twenty additional firstdie layers, and/or at least twenty-five additional first die layers.

A4. The method of any of paragraphs A1-A3, wherein when the methodcomprises forming the second die half, the forming the second die halfcomprises:

cutting one or more additional second die layers to form additionalrespective portions of the second die cavity;

stacking the additional second die layers between the third layer andthe fourth layer such that the additional respective portions of thesecond die cavity are positioned with respect to the first portion ofthe second die cavity and the second portion of the second die cavity,to form the second die cavity; and

fastening the additional second die layers to the third layer and thefourth layer to form the second die half.

A4.1 The method of paragraph A4, wherein the fastening the additionalsecond die layers comprises bolting the additional second die layers tothe third layer and the fourth layer.

A5. The method of paragraph A4 or A4.1, wherein the cutting theadditional second die layers comprises cutting at least one additionalsecond die layer, at least two additional second die layers, at leastthree additional second die layers, at least four additional second dielayers, at least five additional second die layers, at least sixadditional second die layers, at least seven additional second dielayers, at least eight additional second die layers, at least nineadditional second die layers, at least ten additional second die layers,at least fifteen additional second die layers, at least twentyadditional second die layers, and/or at least twenty-five additionalsecond die layers.

A6. The method of any of paragraphs A1-A5, wherein the forming the firstdie half further comprises securing a first baseplate to one of thefirst layer and the second layer.

A7. The method of paragraph A6, wherein the first baseplate is thickerthan the first layer and/or the second layer.

A8. The method of paragraph A6 or A7, wherein the first baseplate doesnot form a portion of the first die cavity.

A8.1. The method of any of paragraphs A6-A8, further comprising removingthe first baseplate from the first die half, and securing the firstbaseplate to a different respective die half.

A8.2. The method of any of paragraphs A6-A8.1, wherein the securing thefirst baseplate comprises securing and reusing a first baseplate thathas been removed from a different respective die half.

A9. The method of any of paragraphs A1-A8.2, wherein when the methodcomprises forming the second die half, the forming the second die halffurther comprises securing a second baseplate to one of the third layerand the fourth layer.

A10. The method of paragraph A9, wherein the second baseplate is thickerthan the third layer and/or the fourth layer.

A11. The method of paragraph A9 or A10, wherein the second baseplatedoes not form a portion of the second die cavity.

A11.1. The method of any of paragraphs A9-A11, further comprisingremoving the second baseplate from the second die half, and securing thesecond baseplate to a different respective die half.

A11.2. The method of any of paragraphs A9-A11.1, wherein the securingthe second baseplate comprises securing and reusing a second baseplatethat has been removed from a different respective die half.

A12. The method of any of paragraphs A1-A11.2, wherein the fastening thefirst layer to the second layer comprises bolting the first layer to thesecond layer.

A12.1. The method of any of paragraphs A1-A11, wherein the fastening thefirst layer to the second layer comprises inserting or applying a fillermaterial configured to fill any irregular gaps between respectiveadjacent layers.

A13. The method of any of paragraphs A1-A12.1, wherein the fastening thefirst layer to the second layer comprises binding the first layer, thesecond layer, and/or any additional first die layers together using afirst plurality of fasteners that extend through at least a portion ofeach respective layer, thereby forming a first laminate of the first diehalf.

A13.1. The method of paragraph A13, wherein each of the first pluralityof fasteners is spaced apart from the first die cavity.

A14. The method of any of paragraphs A1-A13.1, wherein when the methodcomprises forming the second die half, the fastening the third layer tothe fourth layer comprises bolting the third layer to the fourth layer.

A15. The method of any of paragraphs A1-A14, wherein when the methodcomprises forming the second die half, the fastening the third layer tothe fourth layer comprises binding the third layer, the fourth layer,and/or any additional second die layers together using a secondplurality of fasteners that extend through at least a portion of eachrespective layer, thereby forming a second laminate of the second diehalf.

A15.1. The method of paragraph A15, wherein each of the second pluralityof fasteners is spaced apart from the second die cavity.

A15.2. The method of any of paragraphs A1-A15.1, wherein when the methodcomprises forming the second die half, the fastening the third layer tothe fourth layer comprises inserting or applying a filler materialconfigured to fill any irregular gaps between respective adjacentlayers.

A16. The method of any of paragraphs A1-A15.2, further comprisingpositioning the first die half with respect to the second die half suchthat the first die cavity faces the second die cavity.

A17. The method of paragraph A16, wherein the positioning the first diehalf with respect to the second die half comprises positioning the firstdie half such that a/the first baseplate of the first die half and a/thesecond baseplate of the second die half are opposite one another, withthe first die cavity and the second die cavity positioned therebetween.

A18. The method of any of paragraphs A1-A17, wherein at least one of thefirst layer, the second layer, a/the third layer, a/the fourth layer,a/the first baseplate, a/the second baseplate, any additional first dielayer of the first die half, and/or any additional second die layer ofthe second die half is formed of a different material or grade ofmaterial than at least one other of the first layer, the second layer,the third layer, the fourth layer, the first baseplate, the secondbaseplate, any additional first die layer of the first die half, and/orany additional second die layer of the second die half.

A19. The method of any of paragraphs A1-A18, wherein the first layer isformed of a different material than the second layer.

A20. The method of any of paragraphs A1-A19, wherein the first layer isformed of a stronger material than the second layer.

A20.1. The method of any of paragraphs A1-A20, wherein at least onerespective layer of the first die half comprises strip steel.

A20.2. The method of any of paragraphs A1-A20.1, wherein all respectivelayers of the first die half comprise strip steel.

A21. The method of any of paragraphs A1-A20.2, wherein a/the third layeris formed of a different material than the fourth layer.

A22. The method of any of paragraphs A1-A21, wherein a/the third layeris formed of a stronger material than the fourth layer.

A22.1. The method of any of paragraphs A1-A22, wherein at least onerespective layer of the second die half comprises strip steel.

A22.2. The method of any of paragraphs A1-A22.1, wherein all respectivelayers of the second die half comprise strip steel.

A23. The method of any of paragraphs A1-A22.2, wherein the first diehalf and the second die half are configured to cooperate with oneanother such that the first layer of the first die half faces thea/third layer of the second die half.

A24. The method of any of paragraphs A1-A23, further comprisinganalyzing the geometry and/or contours of a given part to determinedesired layer thicknesses and/or the number of layers for each of thefirst die half and the second die half to accommodate loads and stressesduring forging of the part.

A24.1. The method of any of paragraphs A1-A24, wherein the part is ametallic part.

A25. The method of any of paragraphs A1-A24.1, further comprisingencapsulating a sensor in the first die half and/or in the second diehalf, wherein the sensor is configured to monitor and/or measure datafrom the first die half and/or the second die half, during forging ofthe part.

A26. The method of any of paragraphs A1-A25, further comprising forminga cooling channel in the first die half and/or in the second die half,wherein the cooling channel extends through one or more layers of thefirst die half and/or one or more layers of the second die half, andwherein the cooling channel is configured to deliver a cooling fluid tothe first die half and/or the second die half during forging of thepart.

A26.1. The method of paragraph A26, further comprising flowing a coolingfluid and/or a cooling gas through the cooling channel to cool the firstdie half and/or the second die half.

A26.2. The method of paragraph A26 or A26.1, further comprising flowinga protective atmospheric gas and/or a lubricant through the coolingchannel.

A27. The method of any of paragraphs A1-A26.2, further comprisingforming a heating channel in the first die half and/or in the second diehalf, wherein the heating channel extends through one or more layers ofthe first die half and/or one or more layers of the second die half, andwherein the heating channel is configured to deliver a heating elementto the first die half and/or the second die half during forging of thepart.

A27.1. The method of paragraph A27, further comprising flowing a heatingfluid and/or a heating gas through the heating channel to heat the firstdie half and/or the second die half.

A27.2. The method of paragraph A27 or A27.1, further comprisingpositioning a heating cartridge within the heating channel, wherein theheating cartridge is configured to provide heat to the first die halfand/or the second die half.

A27.3. The method of any of paragraphs A27-A27.2, further comprisingflowing a protective atmospheric gas and/or a lubricant through theheating channel.

A28. The method of any of paragraphs A1-A27.3, wherein the cutting thefirst layer and the cutting the second layer comprise water jet cutting.

A29. The method of any of paragraphs A1-A28, wherein when the methodcomprises forming the second die half, the cutting the third layer andthe cutting the fourth layer comprise water jet cutting.

A30. The method of any of paragraphs A1-A29, further comprising forminga first slot in the first die half and positioning a first strain gaugewithin the first slot, wherein the first strain gauge is configured tomeasure and/or monitor strain within one or more layers of the first diehalf.

A31. The method of paragraph A30, wherein the forming the first slotcomprises forming the first slot in the second layer of the first diehalf.

A32. The method of any of paragraphs A1-A31, further comprising forminga second slot in the second die half and positioning a second straingauge within the second slot, wherein the second strain gauge isconfigured to measure and/or monitor strain within one or more layers ofthe second die half.

A33. The method of paragraph A32, wherein the forming the second slotcomprises forming the second slot in the fourth layer of the second diehalf.

A34. The method of any of paragraphs A1-A33, further comprisingcalculating a number of fasteners, size of fasteners, and/or placementof fasteners for fastening the layers of the first die half together.

A34.1. The method of paragraph A34, wherein the calculating comprisesdetermining the number, size, and/or placement of fasteners sufficientto prevent introduction of material from the preform into spaces betweenadjacent respective layers of the first die half during forging of thepart.

A34.2. The method of paragraph A34 or A34.1, wherein the calculatingcomprises determining the number, size, and/or placement of fastenerssufficient to maintain integrity of the first die half during forging ofthe part.

A35. The method of any of paragraphs A1-A34.2, further comprisingcalculating a number of fasteners, size of fasteners, and/or placementof fasteners for fastening the layers of the second die half together.

A35.1. The method of paragraph A35, wherein the calculating comprisesdetermining the number, size, and/or placement of fasteners sufficientto prevent introduction of material from the preform into spaces betweenadjacent respective layers of the second die half during forging of thepart.

A35.2. The method of paragraph A35 or A35.1, wherein the calculatingcomprises determining the number, size, and/or placement of fastenerssufficient to maintain integrity of the second die half during forgingof the part.

A36. The method of any of paragraphs A1-A35.2, further comprisingincorporating drafts and/or fillets into the first die half and/or thesecond die half, wherein the drafts and/or fillets are configured tofacilitate removal of the part from the first die half and the seconddie half after forging and/or to facilitate metal flow within the firstdie cavity and/or the second die cavity during forging.

A36.1. The method of any of paragraphs A1-A36, further comprisingdressing one or more interfaces between adjacent respective layers, ofthe first die half and/or the second die have, to create smooth,continuous layer interfaces and/or die cavities.

A37. The method of any of paragraphs A1-A36.1, wherein the first diehalf and the second die half are configured to minimize the presence ofthin plate sections and small radii.

A38. The method of any of paragraphs A1-A37, further comprising securinga first reinforcing element to a first outer surface of the first diehalf, wherein the first reinforcing element is configured to strengthenthe first die half and/or resist movement of the respective layers ofthe first die half with respect to one another.

A39. The method of paragraph A38, wherein the first reinforcing elementcomprises a square bar.

A40. The method of paragraph A38 or A39, wherein the securing the firstreinforcing element comprises welding the first reinforcing element tothe first die half.

A41. The method of any of paragraphs A38-A40, wherein the first outersurface is formed by the second layer of the first die half.

A42. The method of any of paragraphs A38-A40, wherein the first outersurface is formed by a/the first baseplate of the first die half.

A43. The method of any of paragraphs A1-A42, further comprising securinga second reinforcing element to a second outer surface of the second diehalf, wherein the second reinforcing element is configured to strengthenthe second die half and/or resist movement of the respective layers ofthe second die half with respect to one another.

A44. The method of paragraph A43, wherein the second reinforcing elementcomprises a square bar.

A45. The method of paragraph A43 or A44, wherein the securing the secondreinforcing element comprises welding the second reinforcing element tothe second die half.

A46. The method of any of paragraphs A43-A45, wherein the second outersurface is formed by the fourth layer of the second die half.

A47. The method of any of paragraphs A43-A45, wherein the second outersurface is formed by a/the second baseplate of the second die half.

A48. The method of any of paragraphs A1-A47, further comprising coatingone or more layers of the first die half and/or one or more layers ofthe second die half with a metallic and/or ceramic coating, wherein thecoating is configured to lubricate and/or prevent wear on the first diehalf and/or the second die half.

A49. The method of paragraph A48, wherein the coating one or more layerscomprises flame spraying, plasma spraying, forming a metal skin,diffusion bonding and/or brazing.

B1. A forging die for forging a part from a preform, the forging diecomprising:

-   -   a first die half, wherein the first die half comprises:        -   a first layer cut to form a first portion of a first die            cavity;        -   a second layer cut to form a second portion of the first die            cavity, wherein the first layer and the second layer are            configured to be stacked together such that the first            portion of the first die cavity and the second portion of            the first die cavity are positioned with respect to one            another to form the first die cavity; and        -   a first plurality of fasteners fastening the first layer and            the second layer together to form the first die half; and    -   a second die half, wherein the second die half and the first die        half are configured to cooperate with one another such that the        first die cavity faces the second die half and such that the        first die cavity is configured to receive at least a portion of        the preform, and wherein the forging die is configured to forge        the part from the preform when the first die half and the second        die half are pressed together

B1.1. The forging die of paragraph B1, wherein the first layer and thesecond layer are configured to be cut before they are stacked andfastened together.

B2. The forging die of any of paragraphs B1-B1.1, wherein the first diehalf comprises one or more additional first die layers each cut to forman additional respective portion of the first die cavity, wherein eachadditional first die layer is configured to be stacked between the firstlayer and the second layer such that the additional respective portionsof the first die cavity are positioned with respect to the first portionof the first die cavity and the second portion of the first die cavity,to form the first die cavity.

B3. The forging die of paragraph B2, wherein the one or more additionalfirst die layers are fastened to the first layer and the second layer toform the first die half.

B4. The forging die of paragraph B2 or B3, wherein the one or moreadditional first die layers are fastened to the first layer and thesecond layer via a first plurality of bolts.

B5. The forging die of any of paragraphs B2-B4, wherein the one or moreadditional first die layers comprises at least one additional first dielayer, at least two additional first die layers, at least threeadditional first die layers, at least four additional first die layers,at least five additional first die layers, at least six additional firstdie layers, at least seven additional first die layers, at least eightadditional first die layers, at least nine additional first die layers,at least ten additional first die layers, at least fifteen additionalfirst die layers, at least twenty additional first die layers, and/or atleast twenty-five additional first die layers.

B6. The forging die of any of paragraphs B1-B5, wherein the second diehalf comprises:

-   -   a third layer cut to form a first portion of a second die        cavity;    -   a fourth layer cut to form a second portion of the second die        cavity, wherein the third layer and the fourth layer are        configured to be stacked together such that the first portion of        the second die cavity and the second portion of the second die        cavity are positioned with respect to one another to form the        second die cavity; and    -   a second plurality of fasteners fastening the third layer and        the fourth layer together to form the second die half;

wherein the second die half and the first die half are configured tocooperate with one another such that the first die cavity faces thesecond die cavity and such that the first die cavity and the second diecavity are each configured to receive a respective portion of thepreform, and wherein the forging die is configured to forge the partfrom the preform when the first die half and the second die half arepressed together.

B7. The forging die of paragraph B6, wherein the third layer and thefourth layer are configured to be cut before they are stacked andfastened together.

B8. The forging die of any of paragraphs B6-B7, wherein the second diehalf comprises one or more additional second die layers each cut to forman additional respective portion of the second die cavity, wherein eachadditional second die layer is configured to be stacked between thethird layer and the fourth layer such that the additional respectiveportions of the second die cavity are positioned with respect to thefirst portion of the second die cavity and the second portion of thesecond die cavity, to form the second die cavity.

B8.1. The forging die of paragraph B8, wherein the one or moreadditional second die layers are fastened to the third layer and thefourth layer to form the second die half.

B9. The forging die of paragraph B8 or B8.1, wherein the one or moreadditional second die layers are fastened to the third layer and thefourth layer via a second plurality of bolts.

B10. The forging die of any of paragraphs B8-B9, wherein the one or moreadditional second die layers comprises at least one additional seconddie layer, at least two additional second die layers, at least threeadditional second die layers, at least four additional second dielayers, at least five additional second die layers, at least sixadditional second die layers, at least seven additional second dielayers, at least eight additional second die layers, at least nineadditional second die layers, at least ten additional second die layers,at least fifteen additional second die layers, at least twentyadditional second die layers, and/or at least twenty-five additionalsecond die layers.

B11. The forging die of any of paragraphs B1-B10, wherein the first diehalf comprises a first baseplate secured to one of the first layer andthe second layer.

B12. The forging die of paragraph B11, wherein the first baseplate isthicker than the first layer and/or the second layer.

B13. The forging die of paragraph B11 or B12, wherein the firstbaseplate does not form a portion of the first die cavity.

B13.1. The forging die of any of paragraphs B11-B13, wherein the firstbaseplate is configured to support the first die half and/or to reducethe number of layer interfaces of the first die half.

B14. The forging die of any of paragraphs B1-B13.1, wherein the seconddie half comprises a second baseplate secured to one of a/the thirdlayer and a/the fourth layer.

B15. The forging die of paragraph B14, wherein the second baseplate isthicker than the third layer and/or the fourth layer.

B16. The forging die of paragraph B14 or B15, wherein the secondbaseplate does not form a portion of the second die cavity.

B16.1. The forging die of any of paragraphs B14-B16, wherein the secondbaseplate is configured to support the second die half and/or to reducethe number of layer interfaces of the second die half.

B17. The forging die of any of paragraphs B1-B16.1, wherein the firstplurality of fasteners comprises a first plurality of bolts fasteningthe first layer and the second layer together to form the first diehalf.

B18. The forging die of any of paragraphs B1-B17, wherein one or morerespective fasteners of the first plurality of fasteners extends throughat least a portion of each respective layer of the first die half.

B19. The forging die of any of paragraphs B1-B18, wherein one or morerespective fasteners of the first plurality of fasteners extends throughat least two respective layers of the first die half.

B20. The forging die of any of paragraphs B1-B19, wherein eachrespective fastener of the first plurality of fasteners is spaced apartfrom the first die cavity.

B21. The forging die of any of paragraphs B1-B20, wherein a/the secondplurality of fasteners of the second die half comprises a secondplurality of bolts fastening a/the third layer and a/the fourth layertogether to form the second die half.

B22. The forging die of any of paragraphs B1-B21, wherein one or morerespective fasteners of a/the second plurality of fasteners extendsthrough at least a portion of each respective layer of the second diehalf.

B23. The forging die of any of paragraphs B1-B22, wherein one or morerespective fasteners of the second plurality of fasteners extendsthrough at least two respective layers of the second die half.

B24. The forging die of any of paragraphs B1-B23, wherein eachrespective fastener of the second plurality of fasteners is spaced apartfrom the second die cavity.

B25. The forging die of any of paragraphs B1-B24, wherein a/the firstbaseplate of the first die half and a/the second baseplate of the seconddie half are positioned opposite one another, with the first die cavityand the second die cavity positioned therebetween.

B26. The forging die of any of paragraphs B1-B25, wherein at least oneof the first layer, the second layer, a/the third layer, a/the fourthlayer, a/the first baseplate, a/the second baseplate, any additionalfirst die layer of the first die half, and/or any additional second dielayer of the second die half is formed of a different material or gradeof material than at least one other of the first layer, the secondlayer, the third layer, the fourth layer, the first baseplate, thesecond baseplate, any additional first die layer of the first die half,and/or any additional second die layer of the second die half.

B27. The forging die of any of paragraphs B1-B26, wherein the firstlayer is formed of a different material than the second layer.

B28. The forging die of any of paragraphs B1-B27, wherein the firstlayer is formed of a stronger material than the second layer.

B29. The forging die of any of paragraphs B1-B28, wherein at least onerespective layer of the first die half comprises strip steel.

B30. The forging die of any of paragraphs B1-B29, wherein all respectivelayers of the first die half comprise strip steel.

B31. The forging die of any of paragraphs B1-B30, wherein the a/thirdlayer of the second die half is formed of a different material thana/the fourth layer of the second die half.

B32. The forging die of any of paragraphs B1-B31, wherein a/the thirdlayer of the second die half is formed of a stronger material than a/thefourth layer of the second die half.

B33. The forging die of any of paragraphs B1-B32, wherein at least onerespective layer of the second die half comprises strip steel.

B34. The forging die of any of paragraphs B1-B33, wherein all respectivelayers of the second die half comprise strip steel.

B35. The forging die of any of paragraphs B1-B34, wherein the first diehalf and the second die half are arranged with respect to one anothersuch that the first layer of the first die half faces a/the third layerof the second die half.

B36. The forging die of any of paragraphs B1-B35, wherein the forgingdie is configured to have a customizable number of layers, layerthicknesses, and/or layer materials, depending on the geometry and/orcontours of the part.

B36.1. The forging die of any of paragraphs B1-B36, wherein the part isa metallic part.

B37. The forging die of any of paragraphs B1-B36.1, further comprising asensor encapsulated in the first die half and/or in the second die half,wherein the sensor is configured to monitor and/or measure data from thefirst die half and/or the second die half, during forging of the part.

B38. The forging die of any of paragraphs B1-B37, further comprising acooling channel in the first die half and/or in the second die half,wherein the cooling channel extends through one or more layers of thefirst die half and/or one or more layers of the second die half, andwherein the cooling channel is configured to deliver a cooling fluid tothe first die half and/or the second die half during forging of thepart.

B39. The forging die of any of paragraphs B1-B38, further comprising aheating channel in the first die half and/or in the second die half,wherein the heating channel extends through one or more layers of thefirst die half and/or one or more layers of the second die half, andwherein the heating channel is configured to deliver a heating elementto the first die half and/or the second die half during forging of thepart.

B40. The forging die of any of paragraphs B1-B39, wherein each of thefirst layer, the second layer, a/the third layer, and a/the fourth layerare configured to be water jet cut in order to form the first die cavityand the second die cavity, respectively.

B41. The forging die of any of paragraphs B1-B40, further comprising:

a first slot in the first die half; and

a first strain gauge positioned within the first slot, wherein the firststrain gauge is configured to measure and/or monitor strain within oneor more layers of the first die half.

B42. The forging die of paragraph B41, wherein the first slot is formedin the second layer of the first die half.

B43. The forging die of any of paragraphs B1-B42, further comprising:

a second slot in the second die half; and

a second strain gauge positioned within the second slot, wherein thesecond strain gauge is configured to measure and/or monitor strainwithin one or more layers of the second die half.

B44. The forging die of paragraph B43, wherein the second slot is formedin the fourth layer of the second die half.

B45. The forging die of any of paragraphs B1-B44, wherein the firstplurality of fasteners is configured to prevent introduction of materialfrom the preform into spaces between adjacent respective layers of thefirst die half during forging of the part.

B46. The forging die of any of paragraphs B1-B45, wherein the firstplurality of fasteners is configured to maintain integrity of the firstdie half during forging of the part.

B47. The forging die of any of paragraphs B1-B46, wherein the secondplurality of fasteners is configured to prevent introduction of materialfrom the preform into spaces between adjacent respective layers of thesecond die half during forging of the part.

B48. The forging die of any of paragraphs B1-B47, wherein the secondplurality of fasteners is configured to maintain integrity of the seconddie half during forging of the part.

B49. The forging die of any of paragraphs B1-B48, further comprisingdrafts and/or fillets incorporated into the first die half and/or thesecond die half, wherein the drafts and/or fillets are configured tofacilitate removal of the part from the first die half and the seconddie half after forging and/or to facilitate metal flow within the firstdie cavity and/or the second die cavity during forging.

B50. The forging die of any of paragraphs B1-B49, further comprising afirst reinforcing element secured to a first outer surface of the firstdie half, wherein the first reinforcing element is configured tostrengthen the first die half and/or resist movement of the respectivelayers of the first die half with respect to one another.

B51. The forging die of paragraph B50, wherein the first reinforcingelement comprises a first square bar.

B52. The forging die of paragraph B50 or B51, wherein the firstreinforcing element is welded to the first die half.

B53. The forging die of any of paragraphs B50-B52, wherein the firstouter surface is formed by the second layer of the first die half.

B54. The forging die of any of paragraphs B50-B52, wherein the firstouter surface is formed by a/the first baseplate of the first die half.

B55. The forging die of any of paragraphs B1-B54, further comprising asecond reinforcing element secured to a second outer surface of thesecond die half, wherein the second reinforcing element is configured tostrengthen the second die half and/or resist movement of the respectivelayers of the second die half with respect to one another.

B56. The forging die of paragraph B50, wherein the second reinforcingelement comprises a second square bar.

B57. The forging die of paragraph B55 or B56, wherein the secondreinforcing element is welded to the second die half.

B58. The forging die of any of paragraphs B55-B57, wherein the secondouter surface is formed by the fourth layer of the second die half.

B59. The forging die of any of paragraphs B55-B57, wherein the secondouter surface is formed by a/the second baseplate of the second diehalf.

B60. The forging die of any of paragraphs B1-B59, wherein the firstplurality of fasteners comprises at least five, at least ten, at leastfifteen, at least twenty, at least thirty, at least forty, and/or atleast fifty fasteners.

B61. The forging die of any of paragraphs B1-B60, wherein the secondplurality of fasteners comprises at least five, at least ten, at leastfifteen, at least twenty, at least thirty, at least forty, and/or atleast fifty fasteners.

B62. The forging die of any of paragraphs B1-B61, wherein the firstlayer comprises tool steel and the second layer and any additionallayers of the first die half comprise strip steel.

B63. The forging die of any of paragraphs B1-B62, wherein a/the thirdlayer of the second die half comprises tool steel and a/the fourth layerof the second die half and any additional layers of the second die halfcomprise strip steel.

B64. The forging die of any of paragraphs B1-B63, wherein adjacentrespective layers of the first die half contact one another when thefirst die half is assembled.

B65. The forging die of any of paragraphs B1-B64, wherein adjacentrespective layers of the second die half contact one another when thesecond die half is assembled.

B66. The forging die of any of paragraphs B1-B65, wherein eachrespective layer of the first die half is selectively removable from thefirst die half.

B67. The forging die of any of paragraphs B1-B66, wherein eachrespective layer of the second die half is selectively removable fromthe second die half.

B68. The forging die of any of paragraphs B1-B67, wherein the forgingdie is configured such that the first use of the forging die results indeformation of the first layer and a/the third layer of the second diehalf such that a first perimeter ridge is formed around a firstperimeter of the first die cavity and such that a second perimeter ridgeis formed around a second perimeter of a/the second die cavity.

B69. The forging die of any of paragraphs B1-B68, wherein the firstlayer is thicker than the second layer.

B69.1. The forging die of paragraph B69, wherein the first layer is atleast twice as thick as the second layer.

B70. The forging die of any of paragraphs B1-B69.1, wherein a/the thirdlayer of the second die half is thicker than a/the fourth layer of thesecond die half.

B70.1. The forging die of paragraph B70, wherein the third layer is atleast twice as thick as the fourth layer.

B71. The forging die of any of paragraphs B1-B70.1, wherein a/the firstbaseplate is thicker than any other respective layer of the first diehalf.

B71.1. The forging die of paragraph B71, wherein the first baseplate isat least twice as thick as any other respective layer of the first diehalf.

B72. The forging die of any of paragraphs B1-B71.1, wherein a/the secondbaseplate is thicker than any other respective layer of the second diehalf.

B72.1. The forging die of paragraph B72, wherein the second baseplate isat least twice as thick as any other respective layer of the second diehalf.

B73. The forging die of any of paragraphs B1-B72, wherein the firstlayer and a/the third layer of the second die half are 20-40 mm thick,and wherein the second layer and a/the fourth layer of the second diehalf are 10-20 mm thick.

B74. The forging die of any of paragraphs B1-B73, wherein a/the firstbaseplate of the first die half and a/the second baseplate of the seconddie half are 50-90 mm thick.

C1. A method of making a part, the method comprising:

providing a forging die according to any of paragraphs B1-B74;

positioning a preform within the first die cavity and/or a/the seconddie cavity;

pressing the first die half and the second die half together, therebyforging the preform into the part in the first die cavity and/or thesecond die cavity.

C2. The method of paragraph C1, wherein the pressing the first die halfand the second die half together comprises loading the first die halfand the second die half into a forging press and pressing the die halvestogether using the forging press.

C2.1. The method of paragraph C2, wherein the forging press is ahydraulic press.

C2.2. The method of any of paragraphs C2 or C2.1, wherein the pressingthe die halves together using the forging press comprises causing theforging press to have a ram velocity of at least 5 mm/s, and causing theforging press to exert at least 50 MPa of force onto the first die halfand the second die half.

C3. The method of any of paragraphs C1-C2.2, further comprising heatingthe forging die.

C4. The method of any of paragraphs C1-C3, further comprising heatingthe preform, wherein the heating the preform is performed prior to thepositioning the preform within the first die cavity and the second diecavity.

C5. The method of any of paragraphs C1-C4, wherein the preform comprisesa metal alloy.

C6. The method of any of paragraphs C1-05, further comprising removingthe part from the forging die after the pressing the first die half andthe second die half together sufficiently to cause the preform to beformed into the part.

C7. The method of paragraph C6, further comprising repeating each of thepositioning the preform, the pressing the first die half and the seconddie half together, and the removing the part from the forging die aplurality of times, thereby forming a plurality of parts in the forgingdie.

C8. The method of any of paragraphs C1-C7, wherein the providing theforging die comprises performing the method of any of paragraphs A1-A49.

C9. The method of any of paragraphs C1-C8, further comprisingpositioning the forging die in a furnace configured to heat the forgingdie to a minimum temperature of at least 100 degrees C., at least 200degrees C., at least 300 degrees C., at least 400 degrees C., and/or atleast 500 degrees C.

C10. The method of any of paragraphs C1-C9, further comprisingmonitoring and/or measuring strain within the first die half duringforging of the part, using a/the first strain gauge embedded within thefirst die half.

C11. The method of any of paragraphs C1-C10, further comprisingmonitoring and/or measuring strain within the second die half duringforging of the part, using a/the second strain gauge embedded within thesecond die half.

C12. The method of any of paragraphs C1-C11, further comprising flowingcooling fluid into a/the first cooling channel formed in the first diehalf and/or into a/the second cooling channel formed in the second diehalf.

C13. The method of any of paragraphs C1-C12, further comprising flowingheating fluid into a/the first heating channel formed in the first diehalf and/or into a/the second heating channel formed in the second diehalf.

C13.1. The method of paragraph C13, wherein the heating fluid comprisessuperheated water.

C14. The method of any of paragraphs C1-C13.1, further comprisinginspecting and/or monitoring one or more respective layers of the firstdie half and/or one or more respective layers of the second die half.

C15. The method of paragraph C14, wherein the inspecting and/ormonitoring is performed between successive forgings performed by theforging die.

C16. The method of paragraph C14 or C15, wherein the inspecting and/ormonitoring is performed during the forging of the part.

C17. The method of any of paragraphs C14-C16, wherein the inspectingand/or monitoring comprises detecting and/or identifying areas of wearor excessive stress beyond a predetermined threshold within the firstdie half and/or the second die half.

C18. The method of paragraph C17, wherein the detecting and/oridentifying comprises identifying a respective layer of the first diehalf and/or second die half that may be worn or exposed to excessivestress.

C19. The method of any of paragraphs C1-C18, further comprising removingone or more respective layers from the first die half.

C19.1. The method of paragraph C19, further comprising positioning oneor more new respective layers into the first die half, to replaceremoved layers.

C20. The method of any of paragraphs C1-C19.1, further comprisingremoving one or more respective layers from the second die half.

C20.1. The method of paragraph C20, further comprising positioning oneor more new respective layers into the second die half, to replaceremoved layers.

C21. The method of any of paragraphs C1-C20.1, further comprising:

identifying an area of wear within one or more respective layers of thefirst die half and/or second die half;

removing the respective layer or layers having the area of wear from theforging die; and

inserting a replacement layer into the forging die, wherein thereplacement layer is cut to correspond to the respective layer removedfrom the forging die.

D1. A part made according to the method of any of paragraphs C1-C21.

D2. The part of paragraph D1, wherein the part is comprises of a metalalloy.

D3. A part made using the forging die of any of paragraphs B1-B74.

D4. A part according to any of paragraphs D1-D3, wherein the part is apart for an aircraft.

E1. Use of the forging die of any of paragraphs B1-B74 to forge ametallic part.

E2. Use of the forging die of any of paragraphs B1-B74 to forge a partfor an aircraft.

As used herein, the terms “adapted” and “configured” mean that theelement, component, or other subject matter is designed and/or intendedto perform a given function. Thus, the use of the terms “adapted” and“configured” should not be construed to mean that a given element,component, or other subject matter is simply “capable of” performing agiven function but that the element, component, and/or other subjectmatter is specifically selected, created, implemented, utilized,programmed, and/or designed for the purpose of performing the function.It is also within the scope of the present disclosure that elements,components, and/or other recited subject matter that is recited as beingadapted to perform a particular function may additionally oralternatively be described as being configured to perform that function,and vice versa. Similarly, subject matter that is recited as beingconfigured to perform a particular function may additionally oralternatively be described as being operative to perform that function.

As used herein, the terms “selective” and “selectively,” when modifyingan action, movement, configuration, or other activity of one or morecomponents or characteristics of an apparatus, mean that the specificaction, movement, configuration, or other activity is a direct orindirect result of user manipulation of an aspect of, or one or morecomponents of, the apparatus.

As used herein, the term “and/or” placed between a first entity and asecond entity means one of (1) the first entity, (2) the second entity,and (3) the first entity and the second entity. Multiple entries listedwith “and/or” should be construed in the same manner, i.e., “one ormore” of the entities so conjoined. Other entities optionally may bepresent other than the entities specifically identified by the “and/or”clause, whether related or unrelated to those entities specificallyidentified. Thus, as a non-limiting example, a reference to “A and/orB,” when used in conjunction with open-ended language such as“comprising,” may refer, in one example, to A only (optionally includingentities other than B); in another example, to B only (optionallyincluding entities other than A); in yet another example, to both A andB (optionally including other entities). These entities may refer toelements, actions, structures, steps, operations, values, and the like.

The various disclosed elements of apparatuses and steps of methodsdisclosed herein are not required to all apparatuses and methodsaccording to the present disclosure, and the present disclosure includesall novel and non-obvious combinations and subcombinations of thevarious elements and steps disclosed herein. Moreover, one or more ofthe various elements and steps disclosed herein may define independentinventive subject matter that is separate and apart from the whole of adisclosed apparatus or method. Accordingly, such inventive subjectmatter is not required to be associated with the specific apparatusesand methods that are expressly disclosed herein, and such inventivesubject matter may find utility in apparatuses and/or methods that arenot expressly disclosed herein.

The invention claimed is:
 1. A forging die for forging a part from apreform, the forging die comprising: a first die half, wherein the firstdie half comprises: a first layer cut to form a first portion of a firstdie cavity; a second layer cut to form a second portion of the first diecavity, wherein the first layer and the second layer are configured tobe stacked together such that the first portion of the first die cavityand the second portion of the first die cavity are positioned withrespect to one another to form the first die cavity; and a firstplurality of fasteners fastening the first layer and the second layertogether to form the first die half, wherein each fastener of the firstplurality of fasteners extends through at least a portion of each of thefirst layer and the second layer, wherein each fastener of the firstplurality of fasteners is selectively removable from the first die half,and wherein the first plurality of fasteners are sized and placed withrespect to the first die half such that the first plurality of fastenersis configured to prevent introduction of material from the preform intospaces between adjacent respective layers of the first die half duringforging of the part without bonding, brazing, or welding the first layerand the second layer together; and a second die half, wherein the seconddie half and the first die half are configured to cooperate with oneanother such that the first die cavity faces the second die half andsuch that the first die cavity is configured to receive at least aportion of the preform, and wherein the forging die is configured toforge the part from the preform when the first die half and the seconddie half are pressed together.
 2. The forging die according to claim 1,wherein the second die half comprises: a third layer cut to form a firstportion of a second die cavity; a fourth layer cut to form a secondportion of the second die cavity, wherein the third layer and the fourthlayer are configured to be stacked together such that the first portionof the second die cavity and the second portion of the second die cavityare positioned with respect to one another to form the second diecavity; and a second plurality of fasteners fastening the third layerand the fourth layer together to form the second die half, wherein eachfastener of the second plurality of fasteners extends through at least aportion of each of the third layer and the fourth layer, and whereineach fastener of the second plurality of fasteners is selectivelyremovable from the second die half; wherein the second die half and thefirst die half are configured to cooperate with one another such thatthe first die cavity faces the second die cavity and such that the firstdie cavity and the second die cavity are each configured to receive arespective portion of the preform, and wherein the forging die isconfigured to forge the part from the preform when the first die halfand the second die half are pressed together.
 3. The forging dieaccording to claim 2, wherein the second plurality of fasteners are of asufficient second number, size, and/or placement such that the secondplurality of fasteners are configured to prevent introduction ofmaterial from the preform into spaces between adjacent respective layersof the second die half during forging of the part.
 4. The forging dieaccording to claim 2, wherein the first die half comprises one or moreadditional first die layers each cut to form an additional respectiveportion of the first die cavity, wherein each additional first die layeris configured to be stacked between the first layer and the second layersuch that the additional respective portions of the first die cavity arepositioned with respect to the first portion of the first die cavity andthe second portion of the first die cavity, to form the first diecavity, and wherein the second die half comprises one or more additionalsecond die layers each cut to form an additional respective portion ofthe second die cavity, wherein each additional second die layer isconfigured to be stacked between the third layer and the fourth layersuch that the additional respective portions of the second die cavityare positioned with respect to the first portion of the second diecavity and the second portion of the second die cavity, to form thesecond die cavity.
 5. The forging die according to claim 4, wherein thefirst die half comprises a first baseplate secured to the second layer,wherein the first baseplate is thicker than the first layer and thesecond layer, and wherein the first baseplate does not form a portion ofthe first die cavity, wherein the second die half comprises a secondbaseplate secured to the fourth layer, wherein the second baseplate isthicker than the third layer and the fourth layer, wherein the secondbaseplate does not form a portion of the second die cavity, and whereinthe first baseplate of the first die half and the second baseplate ofthe second die half are positioned opposite one another, with the firstdie cavity and the second die cavity positioned therebetween.
 6. Theforging die according to claim 5, wherein the first plurality offasteners are further configured to bind the first baseplate, the firstlayer, the second layer, and the additional first die layers together,wherein each respective fastener of the first plurality of fastenersextends through at least a portion of each respective layer to form thefirst die half, wherein the second plurality of fasteners are furtherconfigured to bind the second baseplate, the third layer, the fourthlayer, and the additional second die layers together, and wherein eachrespective fastener of the second plurality of fasteners extends throughat least a portion of each respective layer to form the second die half.7. The forging die according to claim 4, wherein the one or moreadditional first die layers have varying thicknesses to accommodateloads and stresses during forging of the part, and further wherein theone or more additional second die layers have varying thicknesses toaccommodate loads and stresses during forging of the part.
 8. Theforging die according to claim 4, wherein each respective layer of thefirst die half is selectively removable from the first die half byremoving the first plurality of fasteners.
 9. The forging die accordingto claim 8, wherein each respective layer of the second die half isselectively removable from the second die half by removing the secondplurality of fasteners.
 10. The forging die according to claim 9,further comprising a replacement layer, wherein the replacement layer isconfigured to be inserted into the forging die to replace a worn layerthat has been removed from the first die half or the second die half,and wherein the replacement layer is cut to correspond to the worn layerremoved from the forging die.
 11. The forging die according to claim 2,wherein the first layer is formed of a first material, wherein thesecond layer is formed of a second material, wherein the third layer isformed of a third material, wherein the fourth layer is formed of afourth material, wherein the first material is more wear-resistant, hasa higher hardness, has a higher tensile and/or compression strength,and/or has a higher toughness than the second material, and wherein thethird material is more wear-resistant, has a higher hardness, has ahigher tensile and/or compression strength, and/or has a highertoughness than the fourth material.
 12. The forging die according toclaim 1, further comprising a sensor encapsulated in the first die halfand/or the second die half, wherein the sensor is configured to monitorand measure data from the first die half and/or the second die half,during forging of the part.
 13. The forging die according to claim 1,further comprising a cooling channel in the first die half and/or thesecond die half, wherein the cooling channel extends through one or morelayers of the first die half and/or one or more layers of the second diehalf, and wherein the cooling channel is configured to deliver a coolingfluid to the first die half and/or the second die half during forging ofthe part.
 14. The forging die according to claim 1, further comprising:a first slot in the first die half; and a first strain gauge positionedwithin the first slot, wherein the first strain gauge is configured tomeasure and/or monitor strain within one or more layers of the first diehalf.
 15. The forging die according to claim 1, wherein the first layeris formed of a different material than the second layer.
 16. The forgingdie according to claim 1, wherein at least one respective layer of thefirst die half comprises strip steel.
 17. The forging die according toclaim 1, wherein the forging die is configured such that the first useof the forging die results in deformation of the first layer, such thata first perimeter ridge is formed around a first perimeter of the firstdie cavity.
 18. The forging die according to claim 1, further comprisinga first reinforcing element secured to a first outer surface of thefirst die half, wherein the first reinforcing element is configured toresist movement of the respective layers of the first die half withrespect to one another.
 19. A method of making a part, the methodcomprising: providing a forging die according to claim 1; positioning atleast a portion of the preform within the first die cavity; pressing thefirst die half and the second die half together, thereby forging thepreform; inspecting and/or monitoring one or more respective layers ofthe second die half and/or more respective layers of the second diehalf; identifying areas of wear or excessive stress beyond apredetermined threshold within one or more respective layers of thefirst die half and/or the second die half based on the inspecting and/ormonitoring; removing the respective layer or layers having the area ofwear from the forging die; cutting a replacement layer to correspond tothe respective layer removed from the forging die; and inserting areplacement layer into the forging die in place of the respective layerremoved from the forging die.
 20. The method according to claim 19,wherein the inspecting and/or monitoring is performed between successiveforgings performed by the forging die.